Audi A5 S5 RS5 8T 8F 2007 2016 Factory Service manualAudi A5 S5 RS5 8T 8F 2007 2016 Factory Service manual
DESCRIPTION:
Audi A5 S5 RS5 8T 8F 2007 2016 Factory Service manual – PDF DOWNLOAD
The engine number (“engine code” and “serial number”) can be found at the joint between engine and gearbox -arrow-. ♦
Additionally there is a sticker on the toothed belt cover (top) with engine code and serial number. ♦ Engine codes starting with the letter “C” have four letters (previously three letters).
♦ The first 3 characters of the engine code stand for the engine capacity and the mechanical construction and design. They are stamped onto the cylinder block together with the serial number. ♦ The 4th character indicates the power output and torque of the engine and is determined by the engine control unit. ♦
The engine code can be found on the type plate (in versions for some countries only) and on the vehicle data sticker and the engine control unit. ♦
Fitting locations of the type plate (certain countries only) and the vehicle data sticker ⇒ Maintenance ; Booklet 812 . For engine data refer to ⇒ Technical data for petrol engines; Rep. gr. 00 ; Overview of engines .
TABLE OF CONTENTS:
Audi A5 S5 RS5 8T 8F 2007 2016 Factory Service manual – PDF DOWNLOAD
4-cylinder_direct_injection_engine_(1_8__2_0_ltr__4-valve_-_generation_II)................................................................................................................................................................................................................................................................................................................................................................................................ 1
00 – Technical data................................................................................................................................................................................................................................................................................................................................................................................................................................................... 7
1 Identification.................................................................................................................................................................................................................................................................................................................................................................................................................................................. 7
1.1 Engine identification number/engine data.................................................................................................................................................................................................................................................................................................................................................................................................................. 7
2 Safety precautions.............................................................................................................................................................................................................................................................................................................................................................................................................................................. 8
2.1 Safety precautions when working on the fuel supply system................................................................................................................................................................................................................................................................................................................................................................................................. 8
2.2 Safety precautions when working on vehicles with start/stop system........................................................................................................................................................................................................................................................................................................................................................................................ 8
2.3 Safety precautions when working on the subframe........................................................................................................................................................................................................................................................................................................................................................................................................... 9
2.4 Safety precautions when using testers and measuring instruments during a road test........................................................................................................................................................................................................................................................................................................................................................................ 9
2.5 Safety precautions when working on the ignition system.................................................................................................................................................................................................................................................................................................................................................................................................... 9
2.6 Safety precautions when working on the cooling system..................................................................................................................................................................................................................................................................................................................................................................................................... 10
3 Repair instructions............................................................................................................................................................................................................................................................................................................................................................................................................................................. 11
3.1 Rules for cleanliness..................................................................................................................................................................................................................................................................................................................................................................................................................................... 11
3.2 Foreign particles in engine............................................................................................................................................................................................................................................................................................................................................................................................................................... 11
3.3 Contact corrosion......................................................................................................................................................................................................................................................................................................................................................................................................................................... 11
3.4 Routing and attachment of pipes, hoses and wiring......................................................................................................................................................................................................................................................................................................................................................................................................... 12
3.5 Installing radiators and condensers....................................................................................................................................................................................................................................................................................................................................................................................................................... 12
10 – Removing and installing engine................................................................................................................................................................................................................................................................................................................................................................................................................................... 13
1 Removing and installing engine.................................................................................................................................................................................................................................................................................................................................................................................................................................. 13
1.1 Removing engine........................................................................................................................................................................................................................................................................................................................................................................................................................................... 13
1.2 Securing engine to engine and gearbox support............................................................................................................................................................................................................................................................................................................................................................................................................. 29
1.3 Installing engine......................................................................................................................................................................................................................................................................................................................................................................................................................................... 32
2 Assembly mountings.............................................................................................................................................................................................................................................................................................................................................................................................................................................. 39
2.1 Exploded view - assembly mountings........................................................................................................................................................................................................................................................................................................................................................................................................................ 39
2.2 Removing and installing engine mountings.................................................................................................................................................................................................................................................................................................................................................................................................................. 40
2.3 Supporting engine in installation position................................................................................................................................................................................................................................................................................................................................................................................................................ 41
3 Engine cover panel.............................................................................................................................................................................................................................................................................................................................................................................................................................................. 43
3.1 Removing and installing engine cover panel................................................................................................................................................................................................................................................................................................................................................................................................................ 43
13 – Crankshaft group................................................................................................................................................................................................................................................................................................................................................................................................................................................. 44
1 Cylinder block (pulley end)..................................................................................................................................................................................................................................................................................................................................................................................................................................... 44
1.1 Exploded view - cylinder block (pulley end)............................................................................................................................................................................................................................................................................................................................................................................................................... 44
1.1.1 Exploded view - cylinder block (pulley end), vehicles with hydraulic power steering................................................................................................................................................................................................................................................................................................................................................................. 44
1.1.2 Exploded view - cylinder block (pulley end), vehicles with electromechanical power steering......................................................................................................................................................................................................................................................................................................................................................... 47
1.2 Removing and installing poly V-belt....................................................................................................................................................................................................................................................................................................................................................................................................................... 49
1.2.1 Removing and installing poly V-belt - vehicles with hydraulic power steering........................................................................................................................................................................................................................................................................................................................................................................ 49
1.2.2 Removing and installing poly V-belt - vehicles with electromechanical power steering................................................................................................................................................................................................................................................................................................................................................................ 50
1.3 Removing and installing tensioner for poly V-belt......................................................................................................................................................................................................................................................................................................................................................................................................... 52
1.3.1 Removing and installing tensioner for poly V-belt - vehicles with hydraulic power steering.......................................................................................................................................................................................................................................................................................................................................................... 52
1.3.2 Removing and installing tensioner for poly V-belt - vehicles with electromechanical power steering.................................................................................................................................................................................................................................................................................................................................................. 52
1.4 Removing and installing vibration damper.................................................................................................................................................................................................................................................................................................................................................................................................................. 53
1.5 Removing and installing bracket for ancillaries........................................................................................................................................................................................................................................................................................................................................................................................................... 59
1.5.1 Removing and installing bracket for ancillaries - vehicles with hydraulic power steering............................................................................................................................................................................................................................................................................................................................................................ 59
1.5.2 Removing and installing bracket for ancillaries - vehicles with electromechanical power steering.................................................................................................................................................................................................................................................................................................................................................... 62
2 Cylinder block (gearbox end).................................................................................................................................................................................................................................................................................................................................................................................................................................... 66
2.1 Exploded view - cylinder block (gearbox end).............................................................................................................................................................................................................................................................................................................................................................................................................. 66
2.2 Removing and installing drive plate....................................................................................................................................................................................................................................................................................................................................................................................................................... 67
2.3 Removing and installing sealing flange (gearbox end)...................................................................................................................................................................................................................................................................................................................................................................................................... 68
2.4 Renewing needle bearing in drive plate.................................................................................................................................................................................................................................................................................................................................................................................................................... 70
3 Crankshaft...................................................................................................................................................................................................................................................................................................................................................................................................................................................... 72
3.1 Exploded view - crankshaft................................................................................................................................................................................................................................................................................................................................................................................................................................ 72
3.2 Crankshaft dimensions..................................................................................................................................................................................................................................................................................................................................................................................................................................... 73
3.3 Allocation of main bearing shells......................................................................................................................................................................................................................................................................................................................................................................................................................... 74
3.4 Measuring axial clearance of crankshaft................................................................................................................................................................................................................................................................................................................................................................................................................... 75
3.5 Measuring radial clearance of crankshaft.................................................................................................................................................................................................................................................................................................................................................................................................................. 76
3.6 Removing and installing sender wheel...................................................................................................................................................................................................................................................................................................................................................................................................................... 76
4 Balance shaft................................................................................................................................................................................................................................................................................................................................................................................................................................................... 78
4.1 Exploded view - balance shaft............................................................................................................................................................................................................................................................................................................................................................................................................................. 78
4.2 Removing and installing balance shaft..................................................................................................................................................................................................................................................................................................................................................................................................................... 79
4.2.1 Removing and installing balance shaft (inlet side).................................................................................................................................................................................................................................................................................................................................................................................................. 79
4.2.2 Removing and installing balance shaft (exhaust side)................................................................................................................................................................................................................................................................................................................................................................................................ 82
4.3 Renewing oil seal for balance shaft (inlet side).......................................................................................................................................................................................................................................................................................................................................................................................................... 85
5 Pistons and conrods............................................................................................................................................................................................................................................................................................................................................................................................................................................. 87
5.1 Exploded view - pistons and conrods....................................................................................................................................................................................................................................................................................................................................................................................................................... 87
5.2 Removing and installing pistons........................................................................................................................................................................................................................................................................................................................................................................................................................... 88
5.3 Checking pistons and cylinder bores....................................................................................................................................................................................................................................................................................................................................................................................................................... 90
5.4 Separating parts of new conrod............................................................................................................................................................................................................................................................................................................................................................................................................................ 91
5.5 Checking radial clearance of conrod bearings.............................................................................................................................................................................................................................................................................................................................................................................................................. 92
15 – Cylinder head, valve gear........................................................................................................................................................................................................................................................................................................................................................................................................................................ 93
1 Timing chain cover.............................................................................................................................................................................................................................................................................................................................................................................................................................................. 93
1.1 Exploded view - timing chain cover........................................................................................................................................................................................................................................................................................................................................................................................................................ 93
1.2 Removing and installing timing chain cover................................................................................................................................................................................................................................................................................................................................................................................................................ 95
1.2.1 Removing and installing timing chain cover (top).................................................................................................................................................................................................................................................................................................................................................................................................... 95
1.2.2 Renewing timing chain cover (bottom)................................................................................................................................................................................................................................................................................................................................................................................................................ 95
1.3 Renewing oil seal for vibration damper.................................................................................................................................................................................................................................................................................................................................................................................................................... 99
2 Chain drive..................................................................................................................................................................................................................................................................................................................................................................................................................................................... 102
2.1 Exploded view - camshaft timing chains.................................................................................................................................................................................................................................................................................................................................................................................................................... 102
2.2 Exploded view - drive chain for balance shaft............................................................................................................................................................................................................................................................................................................................................................................................................. 103
2.3 Removing and installing bearing saddle.................................................................................................................................................................................................................................................................................................................................................................................................................... 104
2.4 Removing and installing camshaft timing chain............................................................................................................................................................................................................................................................................................................................................................................................................. 109
2.5 Removing and installing drive chain for balance shaft..................................................................................................................................................................................................................................................................................................................................................................................................... 118
2.6 Checking valve timing..................................................................................................................................................................................................................................................................................................................................................................................................................................... 120
3 Cylinder head................................................................................................................................................................................................................................................................................................................................................................................................................................................... 123
3.1 Exploded view - cylinder head............................................................................................................................................................................................................................................................................................................................................................................................................................. 123
3.1.1 Exploded view - cylinder head (1.8 ltr. engine)..................................................................................................................................................................................................................................................................................................................................................................................................... 123
3.1.2 Exploded view - cylinder head (2.0 ltr. engine with assembly clearance feature)..................................................................................................................................................................................................................................................................................................................................................................... 126
3.1.3 Exploded view - cylinder head (2.0 ltr. engine without assembly clearance feature).................................................................................................................................................................................................................................................................................................................................................................. 129
3.2 Removing and installing cylinder head..................................................................................................................................................................................................................................................................................................................................................................................................................... 132
3.2.1 Removing and installing cylinder head (1.8 ltr. engine)............................................................................................................................................................................................................................................................................................................................................................................................. 132
3.2.2 Removing and installing cylinder head (2.0 ltr. engine with assembly clearance feature)............................................................................................................................................................................................................................................................................................................................................................. 150
3.2.3 Removing and installing cylinder head (2.0 ltr. engine without assembly clearance feature).......................................................................................................................................................................................................................................................................................................................................................... 170
3.3 Checking compression...................................................................................................................................................................................................................................................................................................................................................................................................................................... 179
4 Valve gear...................................................................................................................................................................................................................................................................................................................................................................................................................................................... 181
4.1 Exploded view - valve gear................................................................................................................................................................................................................................................................................................................................................................................................................................ 181
4.1.1 Exploded view - valve gear (1.8 ltr. engine)........................................................................................................................................................................................................................................................................................................................................................................................................ 181
4.1.2 Exploded view - valve gear (2.0 ltr. engine)........................................................................................................................................................................................................................................................................................................................................................................................................ 184
4.2 Removing and installing camshaft.......................................................................................................................................................................................................................................................................................................................................................................................................................... 186
4.2.1 Removing and installing camshaft (1.8 ltr. engine).................................................................................................................................................................................................................................................................................................................................................................................................. 186
4.2.2 Removing and installing camshaft (2.0 ltr. engine).................................................................................................................................................................................................................................................................................................................................................................................................. 199
4.3 Installing ball for slider................................................................................................................................................................................................................................................................................................................................................................................................................................ 215
4.4 Removing and installing camshaft control valve 1 -N205-................................................................................................................................................................................................................................................................................................................................................................................................... 216
4.5 Removing and installing valve stem oil seals.............................................................................................................................................................................................................................................................................................................................................................................................................. 216
4.5.1 Removing and installing valve stem oil seals (cylinder head installed).............................................................................................................................................................................................................................................................................................................................................................................. 216
4.5.2 Removing and installing valve stem oil seals (cylinder head removed)................................................................................................................................................................................................................................................................................................................................................................................ 220
5 Inlet and exhaust valves........................................................................................................................................................................................................................................................................................................................................................................................................................................ 225
5.1 Checking valve guides..................................................................................................................................................................................................................................................................................................................................................................................................................................... 225
5.2 Checking valves........................................................................................................................................................................................................................................................................................................................................................................................................................................... 226
5.3 Valve dimensions.......................................................................................................................................................................................................................................................................................................................................................................................................................................... 226
17 – Lubrication...................................................................................................................................................................................................................................................................................................................................................................................................................................................... 227
1 Sump/oil pump................................................................................................................................................................................................................................................................................................................................................................................................................................................... 227
1.1 Exploded view - sump/oil pump............................................................................................................................................................................................................................................................................................................................................................................................................................. 227
1.2 Engine oil................................................................................................................................................................................................................................................................................................................................................................................................................................................ 230
1.3 Removing and installing sump (bottom section)............................................................................................................................................................................................................................................................................................................................................................................................................. 230
1.4 Removing and installing sump (top section)................................................................................................................................................................................................................................................................................................................................................................................................................ 233
1.5 Removing and installing oil pump.......................................................................................................................................................................................................................................................................................................................................................................................................................... 236
1.6 Removing and installing oil level and oil temperature sender -G266-....................................................................................................................................................................................................................................................................................................................................................................................... 238
2 Engine oil cooler............................................................................................................................................................................................................................................................................................................................................................................................................................................... 239
2.1 Removing and installing engine oil cooler................................................................................................................................................................................................................................................................................................................................................................................................................. 239
3 Crankcase breather.............................................................................................................................................................................................................................................................................................................................................................................................................................................. 240
3.1 Removing and installing oil separator..................................................................................................................................................................................................................................................................................................................................................................................................................... 240
4 Oil filter/oil pressure switch.................................................................................................................................................................................................................................................................................................................................................................................................................................. 241
4.1 Exploded view - oil filter/oil pressure switches.......................................................................................................................................................................................................................................................................................................................................................................................................... 241
4.2 Removing and installing oil pressure switch -F22-......................................................................................................................................................................................................................................................................................................................................................................................................... 242
4.3 Removing and installing oil pressure switch for reduced oil pressure -F378-............................................................................................................................................................................................................................................................................................................................................................................... 243
4.4 Checking oil pressure..................................................................................................................................................................................................................................................................................................................................................................................................................................... 244
4.5 Removing and installing valve for oil pressure control -N428-............................................................................................................................................................................................................................................................................................................................................................................................. 245
19 – Cooling.......................................................................................................................................................................................................................................................................................................................................................................................................................................................... 247
1 Cooling system/coolant.......................................................................................................................................................................................................................................................................................................................................................................................................................................... 247
1.1 Connection diagram - coolant hoses........................................................................................................................................................................................................................................................................................................................................................................................................................ 247
1.1.1 Connection diagram - coolant hoses, vehicles without gear oil heating and without auxiliary heater.................................................................................................................................................................................................................................................................................................................................................. 247
1.1.2 Connection diagram - coolant hoses, vehicles without gear oil heating and with auxiliary heater..................................................................................................................................................................................................................................................................................................................................................... 249
1.1.3 Connection diagram - coolant hoses, vehicles with gear oil heating and without auxiliary heater..................................................................................................................................................................................................................................................................................................................................................... 250
1.1.4 Connection diagram - coolant hoses, vehicles with gear oil heating and with auxiliary heater........................................................................................................................................................................................................................................................................................................................................................ 251
1.2 Checking cooling system for leaks......................................................................................................................................................................................................................................................................................................................................................................................................................... 252
1.3 Draining and filling cooling system....................................................................................................................................................................................................................................................................................................................................................................................................................... 253
2 Coolant pump/thermostat assembly................................................................................................................................................................................................................................................................................................................................................................................................................................ 260
2.1 Exploded view - coolant pump/thermostat................................................................................................................................................................................................................................................................................................................................................................................................................... 260
2.2 Exploded view - coolant valves............................................................................................................................................................................................................................................................................................................................................................................................................................ 262
2.3 Removing and installing electric coolant pump............................................................................................................................................................................................................................................................................................................................................................................................................. 262
2.4 Removing and installing coolant pump...................................................................................................................................................................................................................................................................................................................................................................................................................... 263
2.5 Removing and installing toothed belt for coolant pump..................................................................................................................................................................................................................................................................................................................................................................................................... 265
2.6 Removing and installing thermostat........................................................................................................................................................................................................................................................................................................................................................................................................................ 267
2.7 Checking thermostat....................................................................................................................................................................................................................................................................................................................................................................................................................................... 268
2.8 Removing and installing coolant temperature sender -G62-.................................................................................................................................................................................................................................................................................................................................................................................................. 268
2.9 Removing and installing coolant valves.................................................................................................................................................................................................................................................................................................................................................................................................................... 270
3 Coolant pipes................................................................................................................................................................................................................................................................................................................................................................................................................................................... 272
3.1 Exploded view - coolant pipes............................................................................................................................................................................................................................................................................................................................................................................................................................. 272
3.2 Removing and installing coolant pipes..................................................................................................................................................................................................................................................................................................................................................................................................................... 273
3.2.1 Removing and installing coolant pipe (front)........................................................................................................................................................................................................................................................................................................................................................................................................ 273
3.2.2 Removing and installing small coolant pipe.......................................................................................................................................................................................................................................................................................................................................................................................................... 274
4 Radiator/radiator fans.......................................................................................................................................................................................................................................................................................................................................................................................................................................... 276
4.1 Exploded view - radiator/radiator fans.................................................................................................................................................................................................................................................................................................................................................................................................................... 276
4.2 Removing and installing radiator.......................................................................................................................................................................................................................................................................................................................................................................................................................... 277
4.3 Removing and installing radiator fan -V7-................................................................................................................................................................................................................................................................................................................................................................................................................. 283
4.3.1 Removing and installing radiator fan -V7-........................................................................................................................................................................................................................................................................................................................................................................................................... 283
4.3.2 Removing and installing radiator fan control unit -J293-............................................................................................................................................................................................................................................................................................................................................................................................ 283
21 – Turbocharging/supercharging...................................................................................................................................................................................................................................................................................................................................................................................................................................... 285
1 Turbocharger.................................................................................................................................................................................................................................................................................................................................................................................................................................................... 285
1.1 Exploded view - turbocharger.............................................................................................................................................................................................................................................................................................................................................................................................................................. 285
1.2 Removing and installing turbocharger...................................................................................................................................................................................................................................................................................................................................................................................................................... 290
1.3 Checking vacuum unit for turbocharger..................................................................................................................................................................................................................................................................................................................................................................................................................... 294
1.4 Renewing vacuum unit for turbocharger..................................................................................................................................................................................................................................................................................................................................................................................................................... 296
1.5 Adjusting vacuum unit for turbocharger.................................................................................................................................................................................................................................................................................................................................................................................................................... 297
2 Charge air system............................................................................................................................................................................................................................................................................................................................................................................................................................................... 301
2.1 Exploded view - charge air system......................................................................................................................................................................................................................................................................................................................................................................................................................... 301
2.2 Removing and installing charge air cooler................................................................................................................................................................................................................................................................................................................................................................................................................. 302
2.3 Removing and installing charge pressure sender -G31-...................................................................................................................................................................................................................................................................................................................................................................................................... 305
2.4 Checking charge air system for leaks...................................................................................................................................................................................................................................................................................................................................................................................................................... 305
24 – Mixture preparation - injection.................................................................................................................................................................................................................................................................................................................................................................................................................................. 308
1 Injection system................................................................................................................................................................................................................................................................................................................................................................................................................................................ 308
1.1 Overview of fitting locations - injection system.......................................................................................................................................................................................................................................................................................................................................................................................................... 308
2 Vacuum system................................................................................................................................................................................................................................................................................................................................................................................................................................................... 318
2.1 Removing and installing activated charcoal filter solenoid valve 1 -N80-.................................................................................................................................................................................................................................................................................................................................................................................. 318
2.1.1 Removing and installing activated charcoal filter solenoid valve 1 -N80-, vehicles with all engine codes except CFKA, CPMA, CPMB.................................................................................................................................................................................................................................................................................................................... 318
2.1.2 Removing and installing activated charcoal filter solenoid valve 1 -N80-, vehicles with engine codes CFKA, CPMA, CPMB............................................................................................................................................................................................................................................................................................................................... 319
2.2 Checking dual non-return valve............................................................................................................................................................................................................................................................................................................................................................................................................................ 319
2.3 Checking vacuum system.................................................................................................................................................................................................................................................................................................................................................................................................................................... 321
3 Air cleaner..................................................................................................................................................................................................................................................................................................................................................................................................................................................... 323
3.1 Exploded view - air cleaner housing....................................................................................................................................................................................................................................................................................................................................................................................................................... 323
3.2 Removing and installing air cleaner housing............................................................................................................................................................................................................................................................................................................................................................................................................... 324
4 Intake manifold................................................................................................................................................................................................................................................................................................................................................................................................................................................. 326
4.1 Exploded view - intake manifold........................................................................................................................................................................................................................................................................................................................................................................................................................... 326
4.1.1 Exploded view - intake manifold, vehicles with all engine codes except CFKA, CPMA, CPMB............................................................................................................................................................................................................................................................................................................................................................. 326
4.1.2 Exploded view - intake manifold, vehicles with engine codes CFKA, CPMA, CPMB........................................................................................................................................................................................................................................................................................................................................................................ 329
4.2 Removing and installing intake manifold................................................................................................................................................................................................................................................................................................................................................................................................................... 331
4.3 Removing and installing intake manifold (top section)..................................................................................................................................................................................................................................................................................................................................................................................................... 334
4.4 Removing and installing intake manifold (bottom section).................................................................................................................................................................................................................................................................................................................................................................................................. 338
4.5 Removing and installing throttle valve module -J338-...................................................................................................................................................................................................................................................................................................................................................................................................... 339
4.6 Cleaning throttle valve module............................................................................................................................................................................................................................................................................................................................................................................................................................ 340
4.7 Checking intake manifold change-over function............................................................................................................................................................................................................................................................................................................................................................................................................. 340
5 Injectors....................................................................................................................................................................................................................................................................................................................................................................................................................................................... 343
5.1 Exploded view - fuel rail with injectors.................................................................................................................................................................................................................................................................................................................................................................................................................. 343
5.1.1 Exploded view - fuel rail with injectors, vehicles with all engine codes except CFKA, CPMA, CPMB.................................................................................................................................................................................................................................................................................................................................................... 343
5.1.2 Exploded view - fuel rail with injectors, vehicles with engine codes CFKA, CPMA, CPMB............................................................................................................................................................................................................................................................................................................................................................... 345
5.2 Removing and installing fuel rail......................................................................................................................................................................................................................................................................................................................................................................................................................... 346
5.2.1 Removing and installing fuel rail - vehicles with all engine codes except CFKA, CPMA, CPMB.......................................................................................................................................................................................................................................................................................................................................................... 346
5.2.2 Removing and installing fuel rail - vehicles with engine codes CFKA, CPMA, CPMB..................................................................................................................................................................................................................................................................................................................................................................... 346
5.3 Removing and installing injectors......................................................................................................................................................................................................................................................................................................................................................................................................................... 347
5.4 Cleaning injectors........................................................................................................................................................................................................................................................................................................................................................................................................................................ 351
5.5 Removing and installing cold-start valve -N17-............................................................................................................................................................................................................................................................................................................................................................................................................ 352
6 Senders and sensors............................................................................................................................................................................................................................................................................................................................................................................................................................................. 354
6.1 Removing and installing fuel pressure sender -G247-....................................................................................................................................................................................................................................................................................................................................................................................................... 354
6.2 Checking fuel pressure sender -G247-...................................................................................................................................................................................................................................................................................................................................................................................................................... 355
6.3 Removing and installing air mass meter.................................................................................................................................................................................................................................................................................................................................................................................................................... 357
6.4 Removing and installing intake air temperature sender -G42-............................................................................................................................................................................................................................................................................................................................................................................................... 358
7 High-pressure pump.............................................................................................................................................................................................................................................................................................................................................................................................................................................. 359
7.1 Exploded view - high-pressure pump........................................................................................................................................................................................................................................................................................................................................................................................................................ 359
7.2 Removing and installing high-pressure pump................................................................................................................................................................................................................................................................................................................................................................................................................ 360
8 Lambda probe.................................................................................................................................................................................................................................................................................................................................................................................................................................................... 363
8.1 Exploded view - Lambda probe.............................................................................................................................................................................................................................................................................................................................................................................................................................. 363
8.2 Removing and installing Lambda probe...................................................................................................................................................................................................................................................................................................................................................................................................................... 364
8.2.1 Removing and installing Lambda probe -G39-.......................................................................................................................................................................................................................................................................................................................................................................................................... 364
8.2.2 Removing and installing Lambda probe after catalytic converter -G130-............................................................................................................................................................................................................................................................................................................................................................................... 365
9 Engine control unit............................................................................................................................................................................................................................................................................................................................................................................................................................................. 367
9.1 Wiring and component check................................................................................................................................................................................................................................................................................................................................................................................................................................ 367
9.2 Removing and installing engine control unit -J623-........................................................................................................................................................................................................................................................................................................................................................................................................ 369
26 – Exhaust system................................................................................................................................................................................................................................................................................................................................................................................................................................................... 373
1 Exhaust pipes/silencers......................................................................................................................................................................................................................................................................................................................................................................................................................................... 373
1.1 Exploded view - silencers................................................................................................................................................................................................................................................................................................................................................................................................................................. 373
1.1.1 Exploded view - silencers, vehicles with one rear silencer.......................................................................................................................................................................................................................................................................................................................................................................................... 373
1.1.2 Exploded view - silencers, vehicles with two rear silencers......................................................................................................................................................................................................................................................................................................................................................................................... 377
1.2 Removing and installing front exhaust pipe................................................................................................................................................................................................................................................................................................................................................................................................................ 380
1.3 Separating exhaust pipes/silencers........................................................................................................................................................................................................................................................................................................................................................................................................................ 381
1.3.1 Separating exhaust pipes/silencers - vehicles with one rear silencer................................................................................................................................................................................................................................................................................................................................................................................ 381
1.3.2 Separating exhaust pipes/silencers - vehicles with two rear silencers............................................................................................................................................................................................................................................................................................................................................................................... 383
1.4 Stress-free alignment of exhaust system................................................................................................................................................................................................................................................................................................................................................................................................................... 384
1.4.1 Stress-free alignment of exhaust system - vehicles with one rear silencer........................................................................................................................................................................................................................................................................................................................................................................... 384
1.4.2 Stress-free alignment of exhaust system - vehicles with two rear silencers.......................................................................................................................................................................................................................................................................................................................................................................... 385
1.5 Renewing tailpipes........................................................................................................................................................................................................................................................................................................................................................................................................................................ 387
1.5.1 Renewing tailpipes - vehicles with one rear silencer................................................................................................................................................................................................................................................................................................................................................................................................ 387
1.5.2 Renewing tailpipes - vehicles with two rear silencers............................................................................................................................................................................................................................................................................................................................................................................................... 387
1.6 Checking exhaust system for leaks......................................................................................................................................................................................................................................................................................................................................................................................................................... 388
2 Emission control system......................................................................................................................................................................................................................................................................................................................................................................................................................................... 389
2.1 Exploded view - emission control system................................................................................................................................................................................................................................................................................................................................................................................................................... 389
2.2 Removing and installing catalytic converter............................................................................................................................................................................................................................................................................................................................................................................................................... 390
28 – Ignition system.................................................................................................................................................................................................................................................................................................................................................................................................................................................. 393
1 Ignition system................................................................................................................................................................................................................................................................................................................................................................................................................................................. 393
1.1 Exploded view - ignition system........................................................................................................................................................................................................................................................................................................................................................................................................................... 393
1.2 Test data, spark plugs.................................................................................................................................................................................................................................................................................................................................................................................................................................... 394
1.3 Removing and installing ignition coils with output stages................................................................................................................................................................................................................................................................................................................................................................................................. 394
1.4 Removing and installing knock sensor...................................................................................................................................................................................................................................................................................................................................................................................................................... 396
1.5 Removing and installing Hall senders...................................................................................................................................................................................................................................................................................................................................................................................................................... 397
1.6 Removing and installing engine speed sender -G28-......................................................................................................................................................................................................................................................................................................................................................................................................... 397
4-cylinder_direct_injection_engine_(1_8__2_0_ltr__4-valve_TFSI_-_generation_III).......................................................................................................................................................................................................................................................................................................................................................................................... 398
00 – Technical data................................................................................................................................................................................................................................................................................................................................................................................................................................................... 404
1 Identification.................................................................................................................................................................................................................................................................................................................................................................................................................................................. 404
1.1 Engine identification number/engine data.................................................................................................................................................................................................................................................................................................................................................................................................................. 404
2 Safety precautions.............................................................................................................................................................................................................................................................................................................................................................................................................................................. 405
2.1 Safety precautions when working on the fuel supply system................................................................................................................................................................................................................................................................................................................................................................................................. 405
2.2 Safety precautions when working on vehicles with start/stop system........................................................................................................................................................................................................................................................................................................................................................................................ 405
2.3 Safety precautions when using testers and measuring instruments during a road test........................................................................................................................................................................................................................................................................................................................................................................ 406
2.4 Safety precautions when working on the subframe........................................................................................................................................................................................................................................................................................................................................................................................................... 406
2.5 Safety precautions when working on the ignition system.................................................................................................................................................................................................................................................................................................................................................................................................... 406
2.6 Safety precautions when working on the cooling system..................................................................................................................................................................................................................................................................................................................................................................................................... 407
3 Repair instructions............................................................................................................................................................................................................................................................................................................................................................................................................................................. 408
3.1 Rules for cleanliness..................................................................................................................................................................................................................................................................................................................................................................................................................................... 408
3.2 Foreign particles in engine............................................................................................................................................................................................................................................................................................................................................................................................................................... 408
3.3 Contact corrosion......................................................................................................................................................................................................................................................................................................................................................................................................................................... 408
3.4 Routing and attachment of pipes, hoses and wiring......................................................................................................................................................................................................................................................................................................................................................................................................... 409
3.5 Installing radiators and condensers....................................................................................................................................................................................................................................................................................................................................................................................................................... 409
3.6 Checking vacuum system.................................................................................................................................................................................................................................................................................................................................................................................................................................... 409
10 – Removing and installing engine................................................................................................................................................................................................................................................................................................................................................................................................................................... 411
1 Removing and installing engine.................................................................................................................................................................................................................................................................................................................................................................................................................................. 411
1.1 Removing engine........................................................................................................................................................................................................................................................................................................................................................................................................................................... 411
1.2 Securing engine to engine and gearbox support............................................................................................................................................................................................................................................................................................................................................................................................................. 427
1.3 Installing engine......................................................................................................................................................................................................................................................................................................................................................................................................................................... 429
2 Assembly mountings.............................................................................................................................................................................................................................................................................................................................................................................................................................................. 437
2.1 Exploded view - assembly mountings........................................................................................................................................................................................................................................................................................................................................................................................................................ 437
2.2 Removing and installing engine mountings.................................................................................................................................................................................................................................................................................................................................................................................................................. 438
3 Engine cover panel.............................................................................................................................................................................................................................................................................................................................................................................................................................................. 440
3.1 Removing and installing engine cover panel................................................................................................................................................................................................................................................................................................................................................................................................................ 440
13 – Crankshaft group................................................................................................................................................................................................................................................................................................................................................................................................................................................. 441
1 Cylinder block (pulley end)..................................................................................................................................................................................................................................................................................................................................................................................................................................... 441
1.1 Exploded view - cylinder block (pulley end)............................................................................................................................................................................................................................................................................................................................................................................................................... 441
1.2 Removing and installing poly V-belt....................................................................................................................................................................................................................................................................................................................................................................................................................... 443
1.3 Removing and installing tensioner for poly V-belt......................................................................................................................................................................................................................................................................................................................................................................................................... 444
1.4 Removing and installing vibration damper.................................................................................................................................................................................................................................................................................................................................................................................................................. 445
1.5 Removing and installing bracket for ancillaries........................................................................................................................................................................................................................................................................................................................................................................................................... 452
2 Cylinder block (gearbox end).................................................................................................................................................................................................................................................................................................................................................................................................................................... 456
2.1 Exploded view - cylinder block (gearbox end).............................................................................................................................................................................................................................................................................................................................................................................................................. 456
2.2 Removing and installing drive plate....................................................................................................................................................................................................................................................................................................................................................................................................................... 457
2.3 Removing and installing sealing flange (gearbox end)...................................................................................................................................................................................................................................................................................................................................................................................................... 458
2.4 Renewing needle bearing in drive plate.................................................................................................................................................................................................................................................................................................................................................................................................................... 460
3 Crankshaft...................................................................................................................................................................................................................................................................................................................................................................................................................................................... 463
3.1 Exploded view - crankshaft................................................................................................................................................................................................................................................................................................................................................................................................................................ 463
3.2 Crankshaft dimensions..................................................................................................................................................................................................................................................................................................................................................................................................................................... 464
3.3 Allocation of main bearing shells......................................................................................................................................................................................................................................................................................................................................................................................................................... 465
3.4 Measuring axial clearance of crankshaft................................................................................................................................................................................................................................................................................................................................................................................................................... 466
3.5 Measuring radial clearance of crankshaft.................................................................................................................................................................................................................................................................................................................................................................................................................. 467
3.6 Removing and installing sender wheel...................................................................................................................................................................................................................................................................................................................................................................................................................... 467
4 Balance shaft................................................................................................................................................................................................................................................................................................................................................................................................................................................... 469
4.1 Exploded view - balance shaft............................................................................................................................................................................................................................................................................................................................................................................................................................. 469
4.2 Removing and installing balance shaft..................................................................................................................................................................................................................................................................................................................................................................................................................... 470
4.2.1 Removing and installing balance shaft (inlet side).................................................................................................................................................................................................................................................................................................................................................................................................. 470
4.2.2 Removing and installing balance shaft (exhaust side)................................................................................................................................................................................................................................................................................................................................................................................................ 473
4.3 Renewing oil seal for balance shaft (inlet side).......................................................................................................................................................................................................................................................................................................................................................................................................... 474
5 Pistons and conrods............................................................................................................................................................................................................................................................................................................................................................................................................................................. 477
5.1 Exploded view - pistons and conrods....................................................................................................................................................................................................................................................................................................................................................................................................................... 477
5.2 Removing and installing pistons........................................................................................................................................................................................................................................................................................................................................................................................................................... 478
5.3 Checking pistons and cylinder bores....................................................................................................................................................................................................................................................................................................................................................................................................................... 480
5.4 Separating parts of new conrod............................................................................................................................................................................................................................................................................................................................................................................................................................ 481
5.5 Checking radial clearance of conrod bearings.............................................................................................................................................................................................................................................................................................................................................................................................................. 482
15 – Cylinder head, valve gear........................................................................................................................................................................................................................................................................................................................................................................................................................................ 483
1 Timing chain cover.............................................................................................................................................................................................................................................................................................................................................................................................................................................. 483
1.1 Exploded view - timing chain cover........................................................................................................................................................................................................................................................................................................................................................................................................................ 483
1.2 Removing and installing camshaft control valve 1 -N205- and exhaust camshaft control valve 1 -N318-....................................................................................................................................................................................................................................................................................................................................................... 486
1.3 Removing and installing timing chain cover................................................................................................................................................................................................................................................................................................................................................................................................................ 486
1.3.1 Removing and installing timing chain cover (top).................................................................................................................................................................................................................................................................................................................................................................................................... 486
1.3.2 Renewing timing chain cover (bottom)................................................................................................................................................................................................................................................................................................................................................................................................................ 488
1.4 Renewing oil seal for vibration damper.................................................................................................................................................................................................................................................................................................................................................................................................................... 492
2 Chain drive..................................................................................................................................................................................................................................................................................................................................................................................................................................................... 496
2.1 Exploded view - camshaft timing chains.................................................................................................................................................................................................................................................................................................................................................................................................................... 496
2.2 Exploded view - drive chain for balance shaft............................................................................................................................................................................................................................................................................................................................................................................................................. 498
2.3 Removing and installing bearing saddle.................................................................................................................................................................................................................................................................................................................................................................................................................... 499
2.4 Removing and installing camshaft timing chain............................................................................................................................................................................................................................................................................................................................................................................................................. 503
2.5 Checking chain elongation................................................................................................................................................................................................................................................................................................................................................................................................................................. 515
2.6 Checking valve timing..................................................................................................................................................................................................................................................................................................................................................................................................................................... 516
3 Cylinder head................................................................................................................................................................................................................................................................................................................................................................................................................................................... 520
3.1 Exploded view - cylinder head............................................................................................................................................................................................................................................................................................................................................................................................................................. 520
3.2 Removing and installing cylinder head..................................................................................................................................................................................................................................................................................................................................................................................................................... 522
3.3 Checking compression...................................................................................................................................................................................................................................................................................................................................................................................................................................... 531
4 Valve gear...................................................................................................................................................................................................................................................................................................................................................................................................................................................... 534
4.1 Exploded view - valve gear................................................................................................................................................................................................................................................................................................................................................................................................................................ 534
4.2 Removing and installing camshaft.......................................................................................................................................................................................................................................................................................................................................................................................................................... 538
4.3 Installing ball for slider................................................................................................................................................................................................................................................................................................................................................................................................................................ 554
4.4 Removing and installing actuators for camshaft adjustment................................................................................................................................................................................................................................................................................................................................................................................................. 555
4.5 Removing and installing valve stem oil seals.............................................................................................................................................................................................................................................................................................................................................................................................................. 556
4.5.1 Removing and installing valve stem oil seals (cylinder head installed).............................................................................................................................................................................................................................................................................................................................................................................. 556
4.5.2 Removing and installing valve stem oil seals (cylinder head removed)................................................................................................................................................................................................................................................................................................................................................................................ 561
5 Inlet and exhaust valves........................................................................................................................................................................................................................................................................................................................................................................................................................................ 566
5.1 Checking valve guides..................................................................................................................................................................................................................................................................................................................................................................................................................................... 566
5.2 Valve dimensions.......................................................................................................................................................................................................................................................................................................................................................................................................................................... 567
17 – Lubrication...................................................................................................................................................................................................................................................................................................................................................................................................................................................... 568
1 Sump/oil pump................................................................................................................................................................................................................................................................................................................................................................................................................................................... 568
1.1 Exploded view - sump/oil pump............................................................................................................................................................................................................................................................................................................................................................................................................................. 568
1.2 Removing and installing oil level and oil temperature sender -G266-....................................................................................................................................................................................................................................................................................................................................................................................... 571
1.3 Removing and installing sump (bottom section)............................................................................................................................................................................................................................................................................................................................................................................................................. 571
1.4 Removing and installing oil pump.......................................................................................................................................................................................................................................................................................................................................................................................................................... 575
1.5 Removing and installing sump (top section)................................................................................................................................................................................................................................................................................................................................................................................................................ 577
1.6 Engine oil................................................................................................................................................................................................................................................................................................................................................................................................................................................ 579
2 Engine oil cooler............................................................................................................................................................................................................................................................................................................................................................................................................................................... 580
2.1 Exploded view - engine oil cooler......................................................................................................................................................................................................................................................................................................................................................................................................................... 580
2.2 Removing and installing engine oil cooler................................................................................................................................................................................................................................................................................................................................................................................................................. 580
2.3 Removing and installing mechanical switching valve........................................................................................................................................................................................................................................................................................................................................................................................................ 582
3 Crankcase breather.............................................................................................................................................................................................................................................................................................................................................................................................................................................. 583
3.1 Exploded view - crankcase breather system................................................................................................................................................................................................................................................................................................................................................................................................................. 583
3.2 Removing and installing oil separator..................................................................................................................................................................................................................................................................................................................................................................................................................... 584
4 Oil filter/oil pressure switch.................................................................................................................................................................................................................................................................................................................................................................................................................................. 585
4.1 Exploded view - oil filter................................................................................................................................................................................................................................................................................................................................................................................................................................ 585
4.2 Exploded view - oil pressure switches/oil pressure control................................................................................................................................................................................................................................................................................................................................................................................................ 586
4.3 Removing and installing piston cooling jet control valve -N522-........................................................................................................................................................................................................................................................................................................................................................................................... 587
4.4 Removing and installing valve for oil pressure control -N428-............................................................................................................................................................................................................................................................................................................................................................................................. 587
4.5 Removing and installing oil pressure switch -F22-......................................................................................................................................................................................................................................................................................................................................................................................................... 589
4.6 Removing and installing oil pressure switch for reduced oil pressure -F378-............................................................................................................................................................................................................................................................................................................................................................................... 590
4.7 Removing and installing stage 3 oil pressure switch -F447-................................................................................................................................................................................................................................................................................................................................................................................................ 590
4.8 Checking oil pressure..................................................................................................................................................................................................................................................................................................................................................................................................................................... 591
4.8.1 Checking engine oil pressure........................................................................................................................................................................................................................................................................................................................................................................................................................ 591
4.8.2 Checking oil pressure for piston cavity oil jets.................................................................................................................................................................................................................................................................................................................................................................................................... 593
4.9 Checking oil pressure and oil pressure switch............................................................................................................................................................................................................................................................................................................................................................................................................. 594
19 – Cooling.......................................................................................................................................................................................................................................................................................................................................................................................................................................................... 595
1 Cooling system/coolant.......................................................................................................................................................................................................................................................................................................................................................................................................................................... 595
1.1 Connection diagram - coolant hoses........................................................................................................................................................................................................................................................................................................................................................................................................................ 595
1.2 Checking cooling system for leaks......................................................................................................................................................................................................................................................................................................................................................................................................................... 596
1.3 Draining and filling cooling system....................................................................................................................................................................................................................................................................................................................................................................................................................... 597
2 Coolant pump/thermostat assembly................................................................................................................................................................................................................................................................................................................................................................................................................................ 605
2.1 Exploded view - coolant pump/thermostat................................................................................................................................................................................................................................................................................................................................................................................................................... 605
2.2 Exploded view - coolant temperature senders............................................................................................................................................................................................................................................................................................................................................................................................................... 607
2.3 Removing and installing coolant pump...................................................................................................................................................................................................................................................................................................................................................................................................................... 607
2.4 Removing and installing toothed belt for coolant pump..................................................................................................................................................................................................................................................................................................................................................................................................... 609
2.5 Removing and installing actuator for engine temperature regulation -N493-................................................................................................................................................................................................................................................................................................................................................................................. 610
2.6 Removing and installing coolant temperature sender -G62-.................................................................................................................................................................................................................................................................................................................................................................................................. 612
2.7 Removing and installing radiator outlet coolant temperature sender -G83-.................................................................................................................................................................................................................................................................................................................................................................................. 613
3 Coolant pipes................................................................................................................................................................................................................................................................................................................................................................................................................................................... 615
3.1 Exploded view - coolant pipes............................................................................................................................................................................................................................................................................................................................................................................................................................. 615
3.2 Removing and installing coolant pipes..................................................................................................................................................................................................................................................................................................................................................................................................................... 616
3.2.1 Removing and installing coolant pipe (left-side).................................................................................................................................................................................................................................................................................................................................................................................................... 616
3.2.2 Removing and installing coolant pipe (right-side)................................................................................................................................................................................................................................................................................................................................................................................................... 617
4 Radiator/radiator fans.......................................................................................................................................................................................................................................................................................................................................................................................................................................... 619
4.1 Exploded view - radiator/radiator fans.................................................................................................................................................................................................................................................................................................................................................................................................................... 619
4.2 Removing and installing radiator.......................................................................................................................................................................................................................................................................................................................................................................................................................... 621
4.3 Removing and installing radiator cowl..................................................................................................................................................................................................................................................................................................................................................................................................................... 627
4.4 Removing and installing radiator fan control unit -J293-.................................................................................................................................................................................................................................................................................................................................................................................................. 632
4.5 Removing and installing radiator fans..................................................................................................................................................................................................................................................................................................................................................................................................................... 633
4.5.1 Removing and installing radiator fans -V7-/-V177-, version 1........................................................................................................................................................................................................................................................................................................................................................................................ 633
4.5.2 Removing and installing radiator fans -V7-/-V177-, version 2........................................................................................................................................................................................................................................................................................................................................................................................ 634
21 – Turbocharging/supercharging...................................................................................................................................................................................................................................................................................................................................................................................................................................... 636
1 Turbocharger.................................................................................................................................................................................................................................................................................................................................................................................................................................................... 636
1.1 Exploded view - turbocharger.............................................................................................................................................................................................................................................................................................................................................................................................................................. 636
1.2 Removing and installing turbocharger...................................................................................................................................................................................................................................................................................................................................................................................................................... 639
2 Charge air system............................................................................................................................................................................................................................................................................................................................................................................................................................................... 644
2.1 Exploded view - charge air system......................................................................................................................................................................................................................................................................................................................................................................................................................... 644
2.2 Removing and installing charge air cooler................................................................................................................................................................................................................................................................................................................................................................................................................. 645
2.3 Removing and installing charge pressure sender -G31-...................................................................................................................................................................................................................................................................................................................................................................................................... 648
2.4 Checking charge air system for leaks...................................................................................................................................................................................................................................................................................................................................................................................................................... 648
24 – Mixture preparation - injection.................................................................................................................................................................................................................................................................................................................................................................................................................................. 651
1 Injection system................................................................................................................................................................................................................................................................................................................................................................................................................................................ 651
1.1 Overview of fitting locations - injection system.......................................................................................................................................................................................................................................................................................................................................................................................................... 651
2 Air cleaner..................................................................................................................................................................................................................................................................................................................................................................................................................................................... 658
2.1 Exploded view - air cleaner housing....................................................................................................................................................................................................................................................................................................................................................................................................................... 658
2.2 Removing and installing air cleaner housing............................................................................................................................................................................................................................................................................................................................................................................................................... 659
3 Intake manifold................................................................................................................................................................................................................................................................................................................................................................................................................................................. 660
3.1 Exploded view - intake manifold........................................................................................................................................................................................................................................................................................................................................................................................................................... 660
3.2 Removing and installing intake manifold................................................................................................................................................................................................................................................................................................................................................................................................................... 661
3.3 Removing and installing throttle valve module -J338-...................................................................................................................................................................................................................................................................................................................................................................................................... 664
3.4 Cleaning throttle valve module............................................................................................................................................................................................................................................................................................................................................................................................................................ 665
3.5 Checking intake manifold change-over function............................................................................................................................................................................................................................................................................................................................................................................................................. 666
4 Injectors....................................................................................................................................................................................................................................................................................................................................................................................................................................................... 668
4.1 Exploded view - fuel rail with injectors.................................................................................................................................................................................................................................................................................................................................................................................................................. 668
4.1.1 Exploded view - fuel rail with injectors, FSI engines............................................................................................................................................................................................................................................................................................................................................................................................... 668
4.1.2 Exploded view - fuel rail with injectors, MPI engines............................................................................................................................................................................................................................................................................................................................................................................................... 669
4.2 Removing and installing fuel rail......................................................................................................................................................................................................................................................................................................................................................................................................................... 670
4.3 Removing and installing injectors......................................................................................................................................................................................................................................................................................................................................................................................................................... 671
4.3.1 Removing and installing injectors, FSI engines...................................................................................................................................................................................................................................................................................................................................................................................................... 671
4.3.2 Removing and installing injectors, MPI engines...................................................................................................................................................................................................................................................................................................................................................................................................... 676
4.4 Cleaning injectors........................................................................................................................................................................................................................................................................................................................................................................................................................................ 677
5 Senders and sensors............................................................................................................................................................................................................................................................................................................................................................................................................................................. 679
5.1 Removing and installing fuel pressure sender -G247-....................................................................................................................................................................................................................................................................................................................................................................................................... 679
5.2 Checking fuel pressure sender -G247-...................................................................................................................................................................................................................................................................................................................................................................................................................... 680
5.3 Removing and installing fuel pressure sender for low pressure -G410-...................................................................................................................................................................................................................................................................................................................................................................................... 682
5.4 Removing and installing intake air temperature sender -G42-/intake manifold pressure sender -G71-......................................................................................................................................................................................................................................................................................................................................................... 684
6 High-pressure pump.............................................................................................................................................................................................................................................................................................................................................................................................................................................. 685
6.1 Exploded view - high-pressure pump........................................................................................................................................................................................................................................................................................................................................................................................................................ 685
6.2 Removing and installing high-pressure pump................................................................................................................................................................................................................................................................................................................................................................................................................ 687
7 Lambda probe.................................................................................................................................................................................................................................................................................................................................................................................................................................................... 689
7.1 Exploded view - Lambda probe.............................................................................................................................................................................................................................................................................................................................................................................................................................. 689
7.2 Removing and installing Lambda probe...................................................................................................................................................................................................................................................................................................................................................................................................................... 690
7.2.1 Removing and installing Lambda probe -G39-.......................................................................................................................................................................................................................................................................................................................................................................................................... 690
7.2.2 Removing and installing Lambda probe after catalytic converter -G130-............................................................................................................................................................................................................................................................................................................................................................................... 690
8 Engine control unit............................................................................................................................................................................................................................................................................................................................................................................................................................................. 692
8.1 Removing and installing engine control unit -J623-........................................................................................................................................................................................................................................................................................................................................................................................................ 692
26 – Exhaust system................................................................................................................................................................................................................................................................................................................................................................................................................................................... 696
1 Exhaust pipes/silencers......................................................................................................................................................................................................................................................................................................................................................................................................................................... 696
1.1 Exploded view - silencers................................................................................................................................................................................................................................................................................................................................................................................................................................. 696
1.2 Separating exhaust pipes/silencers........................................................................................................................................................................................................................................................................................................................................................................................................................ 698
1.3 Removing and installing front silencers................................................................................................................................................................................................................................................................................................................................................................................................................... 699
1.4 Renewing tailpipes........................................................................................................................................................................................................................................................................................................................................................................................................................................ 700
1.5 Stress-free alignment of exhaust system................................................................................................................................................................................................................................................................................................................................................................................................................... 701
1.6 Checking exhaust system for leaks......................................................................................................................................................................................................................................................................................................................................................................................................................... 702
2 Emission control system......................................................................................................................................................................................................................................................................................................................................................................................................................................... 703
2.1 Exploded view - emission control system................................................................................................................................................................................................................................................................................................................................................................................................................... 703
2.2 Removing and installing catalytic converter............................................................................................................................................................................................................................................................................................................................................................................................................... 704
28 – Ignition system.................................................................................................................................................................................................................................................................................................................................................................................................................................................. 708
1 Ignition system................................................................................................................................................................................................................................................................................................................................................................................................................................................. 708
1.1 Exploded view - ignition system........................................................................................................................................................................................................................................................................................................................................................................................................................... 708
1.2 Removing and installing ignition coils with output stages................................................................................................................................................................................................................................................................................................................................................................................................. 709
1.3 Removing and installing knock sensor...................................................................................................................................................................................................................................................................................................................................................................................................................... 711
1.4 Removing and installing Hall senders...................................................................................................................................................................................................................................................................................................................................................................................................................... 711
1.4.1 Removing and installing Hall sender -G40-........................................................................................................................................................................................................................................................................................................................................................................................................... 711
1.4.2 Removing and installing Hall sender 3 -G300-........................................................................................................................................................................................................................................................................................................................................................................................................ 712
1.5 Removing and installing engine speed sender -G28-......................................................................................................................................................................................................................................................................................................................................................................................................... 712
4-cylinder_TDI_engine_(2_0_ltr__4-valve_common_rail)...................................................................................................................................................................................................................................................................................................................................................................................................................... 713
00 – Technical data................................................................................................................................................................................................................................................................................................................................................................................................................................................... 719
1 Identification.................................................................................................................................................................................................................................................................................................................................................................................................................................................. 719
1.1 Engine identification number/engine data.................................................................................................................................................................................................................................................................................................................................................................................................................. 719
2 Safety precautions.............................................................................................................................................................................................................................................................................................................................................................................................................................................. 720
2.1 Safety precautions when working on the fuel supply system................................................................................................................................................................................................................................................................................................................................................................................................. 720
2.2 Safety precautions when working on vehicles with start/stop system........................................................................................................................................................................................................................................................................................................................................................................................ 721
2.3 Safety precautions when using testers and measuring instruments during a road test........................................................................................................................................................................................................................................................................................................................................................................ 722
2.4 Safety precautions when working on the subframe........................................................................................................................................................................................................................................................................................................................................................................................................... 722
2.5 Safety precautions when working on the cooling system..................................................................................................................................................................................................................................................................................................................................................................................................... 722
2.6 Safety precautions when working on the exhaust system..................................................................................................................................................................................................................................................................................................................................................................................................... 723
3 Repair instructions............................................................................................................................................................................................................................................................................................................................................................................................................................................. 724
3.1 Rules for cleanliness..................................................................................................................................................................................................................................................................................................................................................................................................................................... 724
3.2 General notes............................................................................................................................................................................................................................................................................................................................................................................................................................................. 724
3.3 General repair instructions............................................................................................................................................................................................................................................................................................................................................................................................................................... 725
3.4 Foreign particles in engine............................................................................................................................................................................................................................................................................................................................................................................................................................... 726
3.5 Contact corrosion......................................................................................................................................................................................................................................................................................................................................................................................................................................... 726
3.6 Routing and attachment of pipes, hoses and wiring......................................................................................................................................................................................................................................................................................................................................................................................................... 726
3.7 Installing radiators and condensers....................................................................................................................................................................................................................................................................................................................................................................................................................... 726
10 – Removing and installing engine................................................................................................................................................................................................................................................................................................................................................................................................................................... 727
1 Removing and installing engine.................................................................................................................................................................................................................................................................................................................................................................................................................................. 727
1.1 Removing engine........................................................................................................................................................................................................................................................................................................................................................................................................................................... 727
1.2 Securing engine to engine and gearbox support............................................................................................................................................................................................................................................................................................................................................................................................................. 741
1.3 Installing engine......................................................................................................................................................................................................................................................................................................................................................................................................................................... 742
2 Assembly mountings.............................................................................................................................................................................................................................................................................................................................................................................................................................................. 749
2.1 Exploded view - assembly mountings........................................................................................................................................................................................................................................................................................................................................................................................................................ 749
2.2 Removing and installing engine mountings.................................................................................................................................................................................................................................................................................................................................................................................................................. 750
2.3 Removing and installing torque reaction support and cross member.......................................................................................................................................................................................................................................................................................................................................................................................... 751
3 Engine cover panel.............................................................................................................................................................................................................................................................................................................................................................................................................................................. 754
3.1 Removing and installing engine cover panel................................................................................................................................................................................................................................................................................................................................................................................................................ 754
13 – Crankshaft group................................................................................................................................................................................................................................................................................................................................................................................................................................................. 755
1 Cylinder block (pulley end)..................................................................................................................................................................................................................................................................................................................................................................................................................................... 755
1.1 Exploded view - poly V-belt drive......................................................................................................................................................................................................................................................................................................................................................................................................................... 755
1.2 Exploded view - sealing flange (pulley end)............................................................................................................................................................................................................................................................................................................................................................................................................... 757
1.3 Removing and installing poly V-belt....................................................................................................................................................................................................................................................................................................................................................................................................................... 758
1.4 Removing and installing tensioner for poly V-belt......................................................................................................................................................................................................................................................................................................................................................................................................... 759
1.5 Removing and installing vibration damper.................................................................................................................................................................................................................................................................................................................................................................................................................. 761
1.6 Removing and installing bracket for ancillaries........................................................................................................................................................................................................................................................................................................................................................................................................... 762
1.7 Renewing crankshaft oil seal (pulley end)................................................................................................................................................................................................................................................................................................................................................................................................................. 764
1.8 Removing and installing sealing flange (pulley end)....................................................................................................................................................................................................................................................................................................................................................................................................... 766
2 Cylinder block (gearbox end).................................................................................................................................................................................................................................................................................................................................................................................................................................... 769
2.1 Exploded view - cylinder block (gearbox end).............................................................................................................................................................................................................................................................................................................................................................................................................. 769
2.2 Removing and installing drive plate....................................................................................................................................................................................................................................................................................................................................................................................................................... 770
2.3 Removing and installing sealing flange (gearbox end)...................................................................................................................................................................................................................................................................................................................................................................................................... 771
2.4 Renewing needle bearing in drive plate.................................................................................................................................................................................................................................................................................................................................................................................................................... 779
3 Crankshaft...................................................................................................................................................................................................................................................................................................................................................................................................................................................... 781
3.1 Exploded view - crankshaft................................................................................................................................................................................................................................................................................................................................................................................................................................ 781
3.2 Crankshaft dimensions..................................................................................................................................................................................................................................................................................................................................................................................................................................... 781
3.3 Measuring radial clearance of crankshaft.................................................................................................................................................................................................................................................................................................................................................................................................................. 782
3.4 Pulling spur gear off crankshaft and shrink-fitting new spur gear......................................................................................................................................................................................................................................................................................................................................................................................... 782
4 Pistons and conrods............................................................................................................................................................................................................................................................................................................................................................................................................................................. 786
4.1 Exploded view - pistons and conrods....................................................................................................................................................................................................................................................................................................................................................................................................................... 786
4.2 Measuring piston projection at TDC........................................................................................................................................................................................................................................................................................................................................................................................................................ 789
4.3 Piston and cylinder dimensions............................................................................................................................................................................................................................................................................................................................................................................................................................ 790
4.4 Separating parts of new conrod............................................................................................................................................................................................................................................................................................................................................................................................................................ 790
4.5 Bearing shells - installation position.................................................................................................................................................................................................................................................................................................................................................................................................................... 791
4.6 Measuring radial clearance of conrods..................................................................................................................................................................................................................................................................................................................................................................................................................... 791
15 – Cylinder head, valve gear........................................................................................................................................................................................................................................................................................................................................................................................................................................ 792
1 Cylinder head................................................................................................................................................................................................................................................................................................................................................................................................................................................... 792
1.1 Exploded view - cylinder head............................................................................................................................................................................................................................................................................................................................................................................................................................. 792
1.2 Exploded view - cylinder head cover....................................................................................................................................................................................................................................................................................................................................................................................................................... 795
1.3 Removing and installing cylinder head..................................................................................................................................................................................................................................................................................................................................................................................................................... 796
1.4 Removing and installing cylinder head cover............................................................................................................................................................................................................................................................................................................................................................................................................... 800
1.5 Checking compression...................................................................................................................................................................................................................................................................................................................................................................................................................................... 801
1.6 Identification of cylinder head gasket.................................................................................................................................................................................................................................................................................................................................................................................................................... 803
2 Toothed belt drive.............................................................................................................................................................................................................................................................................................................................................................................................................................................. 804
2.1 Exploded view - toothed belt.............................................................................................................................................................................................................................................................................................................................................................................................................................. 804
2.2 Removing and installing toothed belt...................................................................................................................................................................................................................................................................................................................................................................................................................... 805
3 Valve gear...................................................................................................................................................................................................................................................................................................................................................................................................................................................... 816
3.1 Exploded view - valve gear................................................................................................................................................................................................................................................................................................................................................................................................................................ 816
3.2 Removing and installing camshaft oil seal................................................................................................................................................................................................................................................................................................................................................................................................................. 818
3.3 Removing and installing camshaft.......................................................................................................................................................................................................................................................................................................................................................................................................................... 819
3.4 Removing and installing valve stem oil seals.............................................................................................................................................................................................................................................................................................................................................................................................................. 827
3.4.1 Removing and installing valve stem oil seals with cylinder head installed........................................................................................................................................................................................................................................................................................................................................................................... 827
3.4.2 Removing and installing valve stem oil seals with cylinder head removed............................................................................................................................................................................................................................................................................................................................................................................. 830
4 Inlet and exhaust valves........................................................................................................................................................................................................................................................................................................................................................................................................................................ 834
4.1 Machining valve seats..................................................................................................................................................................................................................................................................................................................................................................................................................................... 834
4.2 Checking valve guides..................................................................................................................................................................................................................................................................................................................................................................................................................................... 834
4.3 Valve dimensions.......................................................................................................................................................................................................................................................................................................................................................................................................................................... 834
17 – Lubrication...................................................................................................................................................................................................................................................................................................................................................................................................................................................... 835
1 Sump/oil pump................................................................................................................................................................................................................................................................................................................................................................................................................................................... 835
1.1 Exploded view - sump/oil pump............................................................................................................................................................................................................................................................................................................................................................................................................................. 835
1.2 Engine oil................................................................................................................................................................................................................................................................................................................................................................................................................................................ 838
1.3 Removing and installing sump.............................................................................................................................................................................................................................................................................................................................................................................................................................. 838
1.4 Removing and installing oil pump.......................................................................................................................................................................................................................................................................................................................................................................................................................... 842
2 Engine oil cooler............................................................................................................................................................................................................................................................................................................................................................................................................................................... 844
2.1 Removing and installing engine oil cooler................................................................................................................................................................................................................................................................................................................................................................................................................. 844
3 Oil filter/oil pressure switch.................................................................................................................................................................................................................................................................................................................................................................................................................................. 846
3.1 Exploded view - oil filter housing/oil pressure switch.................................................................................................................................................................................................................................................................................................................................................................................................... 846
3.2 Checking oil pressure and oil pressure switch............................................................................................................................................................................................................................................................................................................................................................................................................. 848
3.3 Removing and installing oil filter housing................................................................................................................................................................................................................................................................................................................................................................................................................ 849
3.4 Checking oil level........................................................................................................................................................................................................................................................................................................................................................................................................................................ 850
4 Balance shaft assembly.......................................................................................................................................................................................................................................................................................................................................................................................................................................... 851
4.1 Removing and installing balance shaft assembly............................................................................................................................................................................................................................................................................................................................................................................................................ 851
4.1.1 Removing balance shaft assembly..................................................................................................................................................................................................................................................................................................................................................................................................................... 851
4.1.2 Installing a new balance shaft assembly............................................................................................................................................................................................................................................................................................................................................................................................................. 852
4.1.3 Re-installing a used balance shaft assembly......................................................................................................................................................................................................................................................................................................................................................................................................... 854
19 – Cooling.......................................................................................................................................................................................................................................................................................................................................................................................................................................................... 856
1 Cooling system/coolant.......................................................................................................................................................................................................................................................................................................................................................................................................................................... 856
1.1 Connection diagram - coolant hoses........................................................................................................................................................................................................................................................................................................................................................................................................................ 856
1.1.1 Connection diagram - coolant hoses without 4/2-way valve, vehicles without auxiliary heater......................................................................................................................................................................................................................................................................................................................................................... 856
1.1.2 Connection diagram - coolant hoses without 4/2-way valve, vehicles with auxiliary heater............................................................................................................................................................................................................................................................................................................................................................ 858
1.1.3 Connection diagram - coolant hoses with 4/2-way valve with thermostat, vehicles without auxiliary heater............................................................................................................................................................................................................................................................................................................................................ 859
1.1.4 Connection diagram - coolant hoses with 4/2-way valve with thermostat, vehicles with auxiliary heater............................................................................................................................................................................................................................................................................................................................................... 860
1.2 Checking cooling system for leaks......................................................................................................................................................................................................................................................................................................................................................................................................................... 861
1.3 Draining and filling cooling system....................................................................................................................................................................................................................................................................................................................................................................................................................... 862
2 Coolant pump/thermostat assembly................................................................................................................................................................................................................................................................................................................................................................................................................................ 870
2.1 Exploded view - coolant pump/thermostat................................................................................................................................................................................................................................................................................................................................................................................................................... 870
2.2 Removing and installing pump for exhaust gas recirculation cooler -V400-.................................................................................................................................................................................................................................................................................................................................................................................. 870
2.3 Removing and installing coolant pump...................................................................................................................................................................................................................................................................................................................................................................................................................... 872
2.4 Removing and installing thermostat........................................................................................................................................................................................................................................................................................................................................................................................................................ 873
2.5 Removing and installing 4/2-way valve with thermostat..................................................................................................................................................................................................................................................................................................................................................................................................... 875
2.6 Removing and installing coolant temperature sender -G62-.................................................................................................................................................................................................................................................................................................................................................................................................. 877
2.7 Removing and installing radiator outlet coolant temperature sender -G83-.................................................................................................................................................................................................................................................................................................................................................................................. 878
3 Radiator/radiator fans.......................................................................................................................................................................................................................................................................................................................................................................................................................................... 879
3.1 Exploded view - radiator/radiator fans.................................................................................................................................................................................................................................................................................................................................................................................................................... 879
3.2 Removing and installing radiator.......................................................................................................................................................................................................................................................................................................................................................................................................................... 880
3.3 Removing and installing radiator fan control unit -J293-.................................................................................................................................................................................................................................................................................................................................................................................................. 885
3.4 Removing and installing radiator fans..................................................................................................................................................................................................................................................................................................................................................................................................................... 886
21 – Turbocharging/supercharging...................................................................................................................................................................................................................................................................................................................................................................................................................................... 888
1 Turbocharger.................................................................................................................................................................................................................................................................................................................................................................................................................................................... 888
1.1 Exploded view - turbocharger.............................................................................................................................................................................................................................................................................................................................................................................................................................. 888
1.2 Removing and installing turbocharger...................................................................................................................................................................................................................................................................................................................................................................................................................... 889
2 Charge air system............................................................................................................................................................................................................................................................................................................................................................................................................................................... 894
2.1 Exploded view - charge air system......................................................................................................................................................................................................................................................................................................................................................................................................................... 894
2.2 Removing and installing charge air cooler................................................................................................................................................................................................................................................................................................................................................................................................................. 895
2.3 Removing and installing charge pressure sender -G31-...................................................................................................................................................................................................................................................................................................................................................................................................... 898
2.4 Checking charge air system for leaks...................................................................................................................................................................................................................................................................................................................................................................................................................... 898
23 – Mixture preparation - injection.................................................................................................................................................................................................................................................................................................................................................................................................................................. 901
1 Injection system................................................................................................................................................................................................................................................................................................................................................................................................................................................ 901
1.1 Overview of fitting locations - injection system.......................................................................................................................................................................................................................................................................................................................................................................................................... 901
1.2 Overview - fuel system.................................................................................................................................................................................................................................................................................................................................................................................................................................... 909
1.3 Exploded view - fuel system............................................................................................................................................................................................................................................................................................................................................................................................................................... 911
1.4 Filling and bleeding fuel system.......................................................................................................................................................................................................................................................................................................................................................................................................................... 915
1.5 Checking fuel system for leaks............................................................................................................................................................................................................................................................................................................................................................................................................................ 916
1.6 Checking fuel pressure (low pressure) system.............................................................................................................................................................................................................................................................................................................................................................................................................. 916
2 Vacuum system................................................................................................................................................................................................................................................................................................................................................................................................................................................... 919
2.1 Checking vacuum system.................................................................................................................................................................................................................................................................................................................................................................................................................................... 919
3 Air cleaner..................................................................................................................................................................................................................................................................................................................................................................................................................................................... 920
3.1 Exploded view - air cleaner housing....................................................................................................................................................................................................................................................................................................................................................................................................................... 920
3.2 Removing and installing air filter element................................................................................................................................................................................................................................................................................................................................................................................................................ 921
3.3 Removing and installing air cleaner housing............................................................................................................................................................................................................................................................................................................................................................................................................... 922
4 Intake manifold................................................................................................................................................................................................................................................................................................................................................................................................................................................. 925
4.1 Exploded view - intake manifold........................................................................................................................................................................................................................................................................................................................................................................................................................... 925
4.2 Removing and installing intake manifold................................................................................................................................................................................................................................................................................................................................................................................................................... 925
5 Injectors/high-pressure reservoir (rail)........................................................................................................................................................................................................................................................................................................................................................................................................................ 931
5.1 Checking injectors........................................................................................................................................................................................................................................................................................................................................................................................................................................ 931
5.2 Performing adaption of correction values for injectors.................................................................................................................................................................................................................................................................................................................................................................................................... 931
5.3 Checking for injectors sticking open...................................................................................................................................................................................................................................................................................................................................................................................................................... 932
5.4 Checking return flow rate of injectors with engine running................................................................................................................................................................................................................................................................................................................................................................................................ 933
5.5 Checking return flow rate of injectors at starter cranking speed.......................................................................................................................................................................................................................................................................................................................................................................................... 936
5.6 Checking pressure retention valve in fuel return line..................................................................................................................................................................................................................................................................................................................................................................................................... 937
5.7 Removing and installing injectors......................................................................................................................................................................................................................................................................................................................................................................................................................... 938
5.8 Removing and installing high-pressure pipes............................................................................................................................................................................................................................................................................................................................................................................................................... 944
5.9 Removing and installing high-pressure reservoir (rail).................................................................................................................................................................................................................................................................................................................................................................................................... 947
6 High-pressure pump.............................................................................................................................................................................................................................................................................................................................................................................................................................................. 950
6.1 Removing and installing high-pressure pump................................................................................................................................................................................................................................................................................................................................................................................................................ 950
6.2 Performing first fuel filling operation after installing high-pressure pump............................................................................................................................................................................................................................................................................................................................................................................... 952
7 Senders and sensors............................................................................................................................................................................................................................................................................................................................................................................................................................................. 954
7.1 Checking fuel pressure regulating valve -N276-............................................................................................................................................................................................................................................................................................................................................................................................................ 954
7.2 Removing and installing fuel pressure regulating valve -N276-............................................................................................................................................................................................................................................................................................................................................................................................. 955
7.3 Removing and installing fuel pressure sender -G247-....................................................................................................................................................................................................................................................................................................................................................................................................... 957
7.4 Removing and installing air mass meter -G70-.............................................................................................................................................................................................................................................................................................................................................................................................................. 960
7.5 Removing and installing exhaust gas pressure sensor 1 -G450-.............................................................................................................................................................................................................................................................................................................................................................................................. 960
8 Lambda probe.................................................................................................................................................................................................................................................................................................................................................................................................................................................... 962
8.1 Exploded view - Lambda probe.............................................................................................................................................................................................................................................................................................................................................................................................................................. 962
8.2 Removing and installing Lambda probe...................................................................................................................................................................................................................................................................................................................................................................................................................... 963
9 Engine control unit............................................................................................................................................................................................................................................................................................................................................................................................................................................. 965
9.1 Wiring and component check with test box -V.A.G 1598/42-.................................................................................................................................................................................................................................................................................................................................................................................................. 965
9.2 Removing and installing engine control unit -J623-........................................................................................................................................................................................................................................................................................................................................................................................................ 966
26 – Exhaust system................................................................................................................................................................................................................................................................................................................................................................................................................................................... 970
1 Exhaust pipes/silencers......................................................................................................................................................................................................................................................................................................................................................................................................................................... 970
1.1 Exploded view - silencers................................................................................................................................................................................................................................................................................................................................................................................................................................. 970
1.2 Removing and installing front exhaust pipe................................................................................................................................................................................................................................................................................................................................................................................................................ 972
1.3 Separating exhaust pipes/silencers........................................................................................................................................................................................................................................................................................................................................................................................................................ 973
1.4 Renewing tailpipes........................................................................................................................................................................................................................................................................................................................................................................................................................................ 974
1.5 Stress-free alignment of exhaust system................................................................................................................................................................................................................................................................................................................................................................................................................... 975
1.6 Checking exhaust system for leaks......................................................................................................................................................................................................................................................................................................................................................................................................................... 976
2 Emission control system......................................................................................................................................................................................................................................................................................................................................................................................................................................... 977
2.1 Removing and installing particulate filter................................................................................................................................................................................................................................................................................................................................................................................................................ 977
3 Exhaust gas temperature control................................................................................................................................................................................................................................................................................................................................................................................................................................. 981
3.1 Exploded view - exhaust gas temperature control........................................................................................................................................................................................................................................................................................................................................................................................................... 981
3.2 Removing and installing exhaust gas temperature sender.................................................................................................................................................................................................................................................................................................................................................................................................... 982
3.2.1 Removing and installing exhaust gas temperature sender 1 -G235-..................................................................................................................................................................................................................................................................................................................................................................................... 982
3.2.2 Removing and installing exhaust gas temperature sender 3 -G495-..................................................................................................................................................................................................................................................................................................................................................................................... 984
3.2.3 Removing and installing exhaust gas temperature sender 4 -G648-..................................................................................................................................................................................................................................................................................................................................................................................... 985
4 Exhaust gas recirculation....................................................................................................................................................................................................................................................................................................................................................................................................................................... 988
4.1 Exploded view - exhaust gas recirculation system.......................................................................................................................................................................................................................................................................................................................................................................................................... 988
4.2 Exploded view - exhaust gas recirculation valve -N18- with exhaust gas recirculation potentiometer -G212-................................................................................................................................................................................................................................................................................................................................................. 989
4.3 Removing and installing exhaust gas recirculation valve -N18-............................................................................................................................................................................................................................................................................................................................................................................................. 990
4.4 Removing and installing exhaust gas recirculation cooler.................................................................................................................................................................................................................................................................................................................................................................................................. 991
4.5 Removing and installing vacuum unit for exhaust gas recirculation cooler.................................................................................................................................................................................................................................................................................................................................................................................. 992
5 Exhaust manifold................................................................................................................................................................................................................................................................................................................................................................................................................................................ 995
5.1 Exploded view - exhaust manifold.......................................................................................................................................................................................................................................................................................................................................................................................................................... 995
5.2 Removing and installing exhaust manifold.................................................................................................................................................................................................................................................................................................................................................................................................................. 995
28 – Glow plug system................................................................................................................................................................................................................................................................................................................................................................................................................................................. 997
1 Glow plug system................................................................................................................................................................................................................................................................................................................................................................................................................................................ 997
1.1 Checking glow plug system................................................................................................................................................................................................................................................................................................................................................................................................................................. 997
1.2 Removing and installing glow plug......................................................................................................................................................................................................................................................................................................................................................................................................................... 997
1.3 Different types of glow plugs............................................................................................................................................................................................................................................................................................................................................................................................................................. 999
1.4 Handling ceramic glow plugs............................................................................................................................................................................................................................................................................................................................................................................................................................... 1000
1.5 Removing and installing Hall sender -G40-................................................................................................................................................................................................................................................................................................................................................................................................................. 1000
1.6 Removing and installing engine speed sender -G28-......................................................................................................................................................................................................................................................................................................................................................................................................... 1001
4-cylinder_TDI_engine_(2_0_ltr__4-valve_common_rail_-_generation_II)...................................................................................................................................................................................................................................................................................................................................................................................................... 1003
00 – Technical data................................................................................................................................................................................................................................................................................................................................................................................................................................................... 1011
1 Identification.................................................................................................................................................................................................................................................................................................................................................................................................................................................. 1011
1.1 Engine identification number/engine data.................................................................................................................................................................................................................................................................................................................................................................................................................. 1011
2 Safety precautions.............................................................................................................................................................................................................................................................................................................................................................................................................................................. 1012
2.1 Safety precautions when working on the fuel supply system................................................................................................................................................................................................................................................................................................................................................................................................. 1012
2.2 Safety precautions when working on vehicles with start/stop system........................................................................................................................................................................................................................................................................................................................................................................................ 1014
2.3 Safety precautions when using testers and measuring instruments during a road test........................................................................................................................................................................................................................................................................................................................................................................ 1014
2.4 Safety precautions when working on the cooling system..................................................................................................................................................................................................................................................................................................................................................................................................... 1014
2.5 Safety precautions when working on the subframe........................................................................................................................................................................................................................................................................................................................................................................................................... 1015
2.6 Safety precautions when working on the exhaust system..................................................................................................................................................................................................................................................................................................................................................................................................... 1015
3 Repair instructions............................................................................................................................................................................................................................................................................................................................................................................................................................................. 1016
3.1 Rules for cleanliness..................................................................................................................................................................................................................................................................................................................................................................................................................................... 1016
3.2 General notes............................................................................................................................................................................................................................................................................................................................................................................................................................................. 1016
3.3 General repair instructions............................................................................................................................................................................................................................................................................................................................................................................................................................... 1017
3.4 Foreign particles in engine............................................................................................................................................................................................................................................................................................................................................................................................................................... 1018
3.5 Contact corrosion......................................................................................................................................................................................................................................................................................................................................................................................................................................... 1018
3.6 Routing and attachment of pipes, hoses and wiring......................................................................................................................................................................................................................................................................................................................................................................................................... 1018
3.7 Installing radiators and condensers....................................................................................................................................................................................................................................................................................................................................................................................................................... 1018
10 – Removing and installing engine................................................................................................................................................................................................................................................................................................................................................................................................................................... 1019
1 Removing and installing engine.................................................................................................................................................................................................................................................................................................................................................................................................................................. 1019
1.1 Removing engine........................................................................................................................................................................................................................................................................................................................................................................................................................................... 1019
1.2 Securing engine to engine and gearbox support............................................................................................................................................................................................................................................................................................................................................................................................................. 1041
1.3 Installing engine......................................................................................................................................................................................................................................................................................................................................................................................................................................... 1042
2 Assembly mountings.............................................................................................................................................................................................................................................................................................................................................................................................................................................. 1051
2.1 Exploded view - assembly mountings........................................................................................................................................................................................................................................................................................................................................................................................................................ 1051
2.2 Removing and installing engine mountings.................................................................................................................................................................................................................................................................................................................................................................................................................. 1052
2.3 Removing and installing torque reaction support and cross member.......................................................................................................................................................................................................................................................................................................................................................................................... 1055
3 Engine cover panel.............................................................................................................................................................................................................................................................................................................................................................................................................................................. 1058
3.1 Removing and installing engine cover panel................................................................................................................................................................................................................................................................................................................................................................................................................ 1058
13 – Crankshaft group................................................................................................................................................................................................................................................................................................................................................................................................................................................. 1059
1 Cylinder block (pulley end)..................................................................................................................................................................................................................................................................................................................................................................................................................................... 1059
1.1 Exploded view - poly V-belt drive......................................................................................................................................................................................................................................................................................................................................................................................................................... 1059
1.1.1 Exploded view - poly V-belt drive without power steering pump....................................................................................................................................................................................................................................................................................................................................................................................... 1059
1.1.2 Exploded view - poly V-belt drive with power steering pump.......................................................................................................................................................................................................................................................................................................................................................................................... 1062
1.2 Exploded view - sealing flange (pulley end)............................................................................................................................................................................................................................................................................................................................................................................................................... 1064
1.3 Removing and installing poly V-belt....................................................................................................................................................................................................................................................................................................................................................................................................................... 1064
1.4 Removing and installing tensioner for poly V-belt......................................................................................................................................................................................................................................................................................................................................................................................................... 1067
1.5 Removing and installing vibration damper.................................................................................................................................................................................................................................................................................................................................................................................................................. 1068
1.6 Removing and installing bracket for ancillaries........................................................................................................................................................................................................................................................................................................................................................................................................... 1069
1.7 Renewing crankshaft oil seal (pulley end)................................................................................................................................................................................................................................................................................................................................................................................................................. 1072
1.8 Removing and installing sealing flange (pulley end)....................................................................................................................................................................................................................................................................................................................................................................................................... 1074
2 Cylinder block (gearbox end).................................................................................................................................................................................................................................................................................................................................................................................................................................... 1077
2.1 Exploded view - cylinder block (gearbox end).............................................................................................................................................................................................................................................................................................................................................................................................................. 1077
2.2 Removing and installing drive plate....................................................................................................................................................................................................................................................................................................................................................................................................................... 1078
2.3 Removing and installing sealing flange (gearbox end)...................................................................................................................................................................................................................................................................................................................................................................................................... 1079
2.4 Renewing needle bearing in drive plate.................................................................................................................................................................................................................................................................................................................................................................................................................... 1087
3 Crankshaft...................................................................................................................................................................................................................................................................................................................................................................................................................................................... 1089
3.1 Exploded view - crankshaft................................................................................................................................................................................................................................................................................................................................................................................................................................ 1089
3.2 Crankshaft dimensions..................................................................................................................................................................................................................................................................................................................................................................................................................................... 1090
3.3 Measuring axial clearance of crankshaft................................................................................................................................................................................................................................................................................................................................................................................................................... 1090
3.4 Measuring radial clearance of crankshaft.................................................................................................................................................................................................................................................................................................................................................................................................................. 1090
3.5 Pulling spur gear off crankshaft and shrink-fitting new spur gear......................................................................................................................................................................................................................................................................................................................................................................................... 1091
4 Pistons and conrods............................................................................................................................................................................................................................................................................................................................................................................................................................................. 1094
4.1 Exploded view - pistons and conrods....................................................................................................................................................................................................................................................................................................................................................................................................................... 1094
4.2 Measuring piston projection at TDC........................................................................................................................................................................................................................................................................................................................................................................................................................ 1098
4.3 Piston and cylinder dimensions............................................................................................................................................................................................................................................................................................................................................................................................................................ 1099
4.4 Checking radial clearance of conrod bearings.............................................................................................................................................................................................................................................................................................................................................................................................................. 1099
15 – Cylinder head, valve gear........................................................................................................................................................................................................................................................................................................................................................................................................................................ 1101
1 Cylinder head................................................................................................................................................................................................................................................................................................................................................................................................................................................... 1101
1.1 Exploded view - cylinder head............................................................................................................................................................................................................................................................................................................................................................................................................................. 1101
1.2 Exploded view - cylinder head cover....................................................................................................................................................................................................................................................................................................................................................................................................................... 1103
1.3 Removing and installing cylinder head..................................................................................................................................................................................................................................................................................................................................................................................................................... 1106
1.4 Removing and installing cylinder head cover............................................................................................................................................................................................................................................................................................................................................................................................................... 1115
1.5 Removing and installing seals for injectors............................................................................................................................................................................................................................................................................................................................................................................................................... 1118
1.6 Checking compression...................................................................................................................................................................................................................................................................................................................................................................................................................................... 1119
2 Toothed belt drive.............................................................................................................................................................................................................................................................................................................................................................................................................................................. 1121
2.1 Exploded view - toothed belt.............................................................................................................................................................................................................................................................................................................................................................................................................................. 1121
2.2 Removing and installing toothed belt...................................................................................................................................................................................................................................................................................................................................................................................................................... 1123
3 Valve gear...................................................................................................................................................................................................................................................................................................................................................................................................................................................... 1132
3.1 Exploded view - valve gear................................................................................................................................................................................................................................................................................................................................................................................................................................ 1132
3.2 Measuring axial clearance of camshaft..................................................................................................................................................................................................................................................................................................................................................................................................................... 1133
3.3 Measuring radial clearance of camshaft.................................................................................................................................................................................................................................................................................................................................................................................................................... 1134
3.4 Removing and installing camshaft oil seal................................................................................................................................................................................................................................................................................................................................................................................................................. 1135
3.5 Removing and installing camshaft.......................................................................................................................................................................................................................................................................................................................................................................................................................... 1137
3.6 Checking hydraulic compensation elements.................................................................................................................................................................................................................................................................................................................................................................................................................. 1143
3.7 Removing and installing valve stem oil seals.............................................................................................................................................................................................................................................................................................................................................................................................................. 1143
3.7.1 Removing and installing valve stem oil seals with cylinder head installed........................................................................................................................................................................................................................................................................................................................................................................... 1143
3.7.2 Removing and installing valve stem oil seals with cylinder head removed............................................................................................................................................................................................................................................................................................................................................................................. 1147
4 Inlet and exhaust valves........................................................................................................................................................................................................................................................................................................................................................................................................................................ 1151
4.1 Machining valve seats..................................................................................................................................................................................................................................................................................................................................................................................................................................... 1151
4.2 Checking valve guides..................................................................................................................................................................................................................................................................................................................................................................................................................................... 1151
4.3 Checking valves........................................................................................................................................................................................................................................................................................................................................................................................................................................... 1152
4.4 Valve dimensions.......................................................................................................................................................................................................................................................................................................................................................................................................................................... 1152
17 – Lubrication...................................................................................................................................................................................................................................................................................................................................................................................................................................................... 1153
1 Sump/oil pump................................................................................................................................................................................................................................................................................................................................................................................................................................................... 1153
1.1 Exploded view - sump/oil pump............................................................................................................................................................................................................................................................................................................................................................................................................................. 1153
1.2 Engine oil................................................................................................................................................................................................................................................................................................................................................................................................................................................ 1157
1.3 Checking oil level........................................................................................................................................................................................................................................................................................................................................................................................................................................ 1157
1.4 Removing and installing sump.............................................................................................................................................................................................................................................................................................................................................................................................................................. 1157
1.5 Removing and installing oil pump.......................................................................................................................................................................................................................................................................................................................................................................................................................... 1159
1.6 Removing and installing oil level and oil temperature sender -G266-....................................................................................................................................................................................................................................................................................................................................................................................... 1161
2 Engine oil cooler............................................................................................................................................................................................................................................................................................................................................................................................................................................... 1162
2.1 Removing and installing engine oil cooler................................................................................................................................................................................................................................................................................................................................................................................................................. 1162
3 Oil filter/oil pressure switch.................................................................................................................................................................................................................................................................................................................................................................................................................................. 1163
3.1 Exploded view - oil filter housing/oil pressure switch.................................................................................................................................................................................................................................................................................................................................................................................................... 1163
3.2 Checking oil pressure..................................................................................................................................................................................................................................................................................................................................................................................................................................... 1164
3.3 Checking oil pressure switch -F1-......................................................................................................................................................................................................................................................................................................................................................................................................................... 1164
3.4 Removing and installing oil pressure switch -F1-.......................................................................................................................................................................................................................................................................................................................................................................................................... 1166
3.5 Removing and installing oil filter housing................................................................................................................................................................................................................................................................................................................................................................................................................ 1167
4 Balance shaft assembly.......................................................................................................................................................................................................................................................................................................................................................................................................................................... 1170
4.1 Removing and installing balance shaft assembly............................................................................................................................................................................................................................................................................................................................................................................................................ 1170
4.1.1 Removing balance shaft assembly..................................................................................................................................................................................................................................................................................................................................................................................................................... 1170
4.1.2 Installing a new balance shaft assembly............................................................................................................................................................................................................................................................................................................................................................................................................. 1171
4.1.3 Re-installing a used balance shaft assembly......................................................................................................................................................................................................................................................................................................................................................................................................... 1174
19 – Cooling.......................................................................................................................................................................................................................................................................................................................................................................................................................................................... 1176
1 Cooling system/coolant.......................................................................................................................................................................................................................................................................................................................................................................................................................................... 1176
1.1 Connection diagram - coolant hoses........................................................................................................................................................................................................................................................................................................................................................................................................................ 1176
1.1.1 Connection diagram - coolant hoses, vehicles without auxiliary heater............................................................................................................................................................................................................................................................................................................................................................................... 1176
1.1.2 Connection diagram - coolant hoses, vehicles with auxiliary heater.................................................................................................................................................................................................................................................................................................................................................................................. 1178
1.2 Checking cooling system for leaks......................................................................................................................................................................................................................................................................................................................................................................................................................... 1179
1.3 Draining and filling cooling system....................................................................................................................................................................................................................................................................................................................................................................................................................... 1181
2 Coolant pump/thermostat assembly................................................................................................................................................................................................................................................................................................................................................................................................................................ 1189
2.1 Exploded view - coolant pump/thermostat................................................................................................................................................................................................................................................................................................................................................................................................................... 1189
2.2 Exploded view - pump for exhaust gas recirculation cooler -V400-.......................................................................................................................................................................................................................................................................................................................................................................................... 1191
2.3 Exploded view - continued coolant circulation pump -V50-.................................................................................................................................................................................................................................................................................................................................................................................................. 1192
2.4 Exploded view - coolant valve for gearbox................................................................................................................................................................................................................................................................................................................................................................................................................. 1193
2.5 Removing and installing coolant pump...................................................................................................................................................................................................................................................................................................................................................................................................................... 1194
2.6 Checking thermostat....................................................................................................................................................................................................................................................................................................................................................................................................................................... 1194
2.7 Removing and installing 4/2-way valve with thermostat..................................................................................................................................................................................................................................................................................................................................................................................................... 1194
2.8 Removing and installing coolant temperature sender -G62-.................................................................................................................................................................................................................................................................................................................................................................................................. 1197
2.9 Removing and installing radiator outlet coolant temperature sender -G83-.................................................................................................................................................................................................................................................................................................................................................................................. 1198
2.10 Removing and installing pump for exhaust gas recirculation cooler -V400-................................................................................................................................................................................................................................................................................................................................................................................. 1199
2.11 Removing and installing coolant circulation pump -V50-................................................................................................................................................................................................................................................................................................................................................................................................... 1201
2.12 Removing and installing coolant valve for gearbox -N488-................................................................................................................................................................................................................................................................................................................................................................................................. 1202
3 Coolant pipes................................................................................................................................................................................................................................................................................................................................................................................................................................................... 1204
3.1 Exploded view - coolant pipes............................................................................................................................................................................................................................................................................................................................................................................................................................. 1204
3.2 Removing and installing coolant pipe (top left)........................................................................................................................................................................................................................................................................................................................................................................................................... 1205
3.3 Removing and installing coolant pipe (bottom left)........................................................................................................................................................................................................................................................................................................................................................................................................ 1206
3.4 Removing and installing coolant pipe (rear right)......................................................................................................................................................................................................................................................................................................................................................................................................... 1208
3.5 Removing and installing coolant pipe (rear)............................................................................................................................................................................................................................................................................................................................................................................................................... 1211
4 Radiator/radiator fans.......................................................................................................................................................................................................................................................................................................................................................................................................................................... 1214
4.1 Exploded view - radiator/radiator fans.................................................................................................................................................................................................................................................................................................................................................................................................................... 1214
4.2 Removing and installing radiator.......................................................................................................................................................................................................................................................................................................................................................................................................................... 1215
4.3 Removing and installing radiator cowl with radiator fan................................................................................................................................................................................................................................................................................................................................................................................................... 1218
4.4 Removing and installing radiator fan control unit -J293-.................................................................................................................................................................................................................................................................................................................................................................................................. 1222
4.5 Removing and installing radiator fans..................................................................................................................................................................................................................................................................................................................................................................................................................... 1223
21 – Turbocharging/supercharging...................................................................................................................................................................................................................................................................................................................................................................................................................................... 1225
1 Turbocharger.................................................................................................................................................................................................................................................................................................................................................................................................................................................... 1225
1.1 Exploded view - turbocharger.............................................................................................................................................................................................................................................................................................................................................................................................................................. 1225
1.2 Removing and installing turbocharger...................................................................................................................................................................................................................................................................................................................................................................................................................... 1226
2 Charge air system............................................................................................................................................................................................................................................................................................................................................................................................................................................... 1233
2.1 Overview - charge air system.............................................................................................................................................................................................................................................................................................................................................................................................................................. 1233
2.2 Exploded view - charge air system......................................................................................................................................................................................................................................................................................................................................................................................................................... 1234
2.2.1 Exploded view - charge air system, version 1........................................................................................................................................................................................................................................................................................................................................................................................................ 1234
2.2.2 Exploded view - charge air system, version 2........................................................................................................................................................................................................................................................................................................................................................................................................ 1235
2.3 Removing and installing charge air cooler................................................................................................................................................................................................................................................................................................................................................................................................................. 1236
2.4 Removing and installing charge pressure sender -G31- / intake air temperature sender -G42-................................................................................................................................................................................................................................................................................................................................................................ 1238
2.4.1 Removing and installing charge pressure sender -G31- / intake air temperature sender -G42-, version 1............................................................................................................................................................................................................................................................................................................................................... 1238
2.4.2 Removing and installing charge pressure sender -G31- / intake air temperature sender -G42-, version 2............................................................................................................................................................................................................................................................................................................................................... 1239
2.5 Checking charge air system for leaks...................................................................................................................................................................................................................................................................................................................................................................................................................... 1239
23 – Mixture preparation - injection.................................................................................................................................................................................................................................................................................................................................................................................................................................. 1242
1 Injection system................................................................................................................................................................................................................................................................................................................................................................................................................................................ 1242
1.1 Overview of fitting locations - injection system.......................................................................................................................................................................................................................................................................................................................................................................................................... 1242
1.2 Overview - fuel system.................................................................................................................................................................................................................................................................................................................................................................................................................................... 1249
1.3 Filling and bleeding fuel system.......................................................................................................................................................................................................................................................................................................................................................................................................................... 1250
1.4 Checking fuel system for leaks............................................................................................................................................................................................................................................................................................................................................................................................................................ 1251
2 Vacuum system................................................................................................................................................................................................................................................................................................................................................................................................................................................... 1252
2.1 Checking vacuum system.................................................................................................................................................................................................................................................................................................................................................................................................................................... 1252
3 Air cleaner..................................................................................................................................................................................................................................................................................................................................................................................................................................................... 1253
3.1 Exploded view - air cleaner housing....................................................................................................................................................................................................................................................................................................................................................................................................................... 1253
3.2 Removing and installing air cleaner housing............................................................................................................................................................................................................................................................................................................................................................................................................... 1254
3.2.1 Removing and installing air cleaner (bottom section)................................................................................................................................................................................................................................................................................................................................................................................................ 1254
3.2.2 Removing and installing air filter element.......................................................................................................................................................................................................................................................................................................................................................................................................... 1256
4 Intake manifold................................................................................................................................................................................................................................................................................................................................................................................................................................................. 1258
4.1 Exploded view - intake manifold........................................................................................................................................................................................................................................................................................................................................................................................................................... 1258
4.2 Removing and installing intake manifold................................................................................................................................................................................................................................................................................................................................................................................................................... 1259
4.3 Removing and installing throttle valve module -J338-...................................................................................................................................................................................................................................................................................................................................................................................................... 1262
5 Injectors/high-pressure reservoir (rail)........................................................................................................................................................................................................................................................................................................................................................................................................................ 1263
5.1 Exploded view - injectors................................................................................................................................................................................................................................................................................................................................................................................................................................. 1263
5.2 Checking injectors........................................................................................................................................................................................................................................................................................................................................................................................................................................ 1266
5.3 Performing adaption of correction values for injectors.................................................................................................................................................................................................................................................................................................................................................................................................... 1266
5.4 Checking for injectors sticking open...................................................................................................................................................................................................................................................................................................................................................................................................................... 1267
5.5 Checking return flow rate of injectors with engine running................................................................................................................................................................................................................................................................................................................................................................................................ 1268
5.6 Checking return flow rate of injectors at starter cranking speed.......................................................................................................................................................................................................................................................................................................................................................................................... 1271
5.7 Removing and installing injectors......................................................................................................................................................................................................................................................................................................................................................................................................................... 1272
5.8 Removing and installing high-pressure pipes............................................................................................................................................................................................................................................................................................................................................................................................................... 1278
5.9 Removing and installing high-pressure reservoir (rail).................................................................................................................................................................................................................................................................................................................................................................................................... 1279
6 High-pressure pump.............................................................................................................................................................................................................................................................................................................................................................................................................................................. 1282
6.1 Exploded view - high-pressure pump........................................................................................................................................................................................................................................................................................................................................................................................................................ 1282
6.2 Removing and installing high-pressure pump................................................................................................................................................................................................................................................................................................................................................................................................................ 1283
6.3 Performing first fuel filling operation after installing high-pressure pump............................................................................................................................................................................................................................................................................................................................................................................... 1285
7 Senders and sensors............................................................................................................................................................................................................................................................................................................................................................................................................................................. 1287
7.1 Checking fuel pressure (low pressure)..................................................................................................................................................................................................................................................................................................................................................................................................................... 1287
7.2 Checking fuel pressure regulating valve -N276-............................................................................................................................................................................................................................................................................................................................................................................................................ 1289
7.3 Removing and installing fuel pressure regulating valve -N276-............................................................................................................................................................................................................................................................................................................................................................................................. 1290
7.4 Removing and installing fuel pressure sender -G247-....................................................................................................................................................................................................................................................................................................................................................................................................... 1292
7.5 Removing and installing air mass meter -G70-.............................................................................................................................................................................................................................................................................................................................................................................................................. 1295
8 Lambda probe.................................................................................................................................................................................................................................................................................................................................................................................................................................................... 1296
8.1 Exploded view - Lambda probe.............................................................................................................................................................................................................................................................................................................................................................................................................................. 1296
8.2 Removing and installing Lambda probe...................................................................................................................................................................................................................................................................................................................................................................................................................... 1296
9 Engine control unit............................................................................................................................................................................................................................................................................................................................................................................................................................................. 1298
9.1 Wiring and component check with test box -V.A.G 1598/42-.................................................................................................................................................................................................................................................................................................................................................................................................. 1298
9.2 Removing and installing engine control unit -J623-........................................................................................................................................................................................................................................................................................................................................................................................................ 1299
26 – Exhaust system................................................................................................................................................................................................................................................................................................................................................................................................................................................... 1303
1 Exhaust pipes/silencers......................................................................................................................................................................................................................................................................................................................................................................................................................................... 1303
1.1 Exploded view - silencers................................................................................................................................................................................................................................................................................................................................................................................................................................. 1303
1.2 Removing and installing front exhaust pipe................................................................................................................................................................................................................................................................................................................................................................................................................ 1306
1.3 Separating exhaust pipes/silencers........................................................................................................................................................................................................................................................................................................................................................................................................................ 1307
1.4 Renewing tailpipes........................................................................................................................................................................................................................................................................................................................................................................................................................................ 1308
1.5 Stress-free alignment of exhaust system................................................................................................................................................................................................................................................................................................................................................................................................................... 1309
1.6 Checking exhaust system for leaks......................................................................................................................................................................................................................................................................................................................................................................................................................... 1310
2 Emission control system......................................................................................................................................................................................................................................................................................................................................................................................................................................... 1312
2.1 Removing and installing particulate filter................................................................................................................................................................................................................................................................................................................................................................................................................ 1312
2.2 Removing and installing pressure differential sender -G505-............................................................................................................................................................................................................................................................................................................................................................................................... 1313
3 Exhaust gas temperature control................................................................................................................................................................................................................................................................................................................................................................................................................................. 1315
3.1 Exploded view - exhaust gas temperature control........................................................................................................................................................................................................................................................................................................................................................................................................... 1315
3.2 Removing and installing exhaust gas temperature sender 1 -G235-........................................................................................................................................................................................................................................................................................................................................................................................... 1316
3.3 Removing and installing exhaust gas temperature sender 3 -G495-........................................................................................................................................................................................................................................................................................................................................................................................... 1318
3.4 Removing and installing exhaust gas temperature sender 4 -G648-........................................................................................................................................................................................................................................................................................................................................................................................... 1320
4 Exhaust gas recirculation....................................................................................................................................................................................................................................................................................................................................................................................................................................... 1323
4.1 Exploded view - exhaust gas recirculation system.......................................................................................................................................................................................................................................................................................................................................................................................................... 1323
4.2 Removing and installing exhaust gas recirculation cooler.................................................................................................................................................................................................................................................................................................................................................................................................. 1324
4.3 Checking exhaust gas recirculation cooler change-over..................................................................................................................................................................................................................................................................................................................................................................................................... 1326
5 Exhaust manifold................................................................................................................................................................................................................................................................................................................................................................................................................................................ 1328
5.1 Exploded view - exhaust manifold.......................................................................................................................................................................................................................................................................................................................................................................................................................... 1328
5.2 Removing and installing exhaust manifold.................................................................................................................................................................................................................................................................................................................................................................................................................. 1329
28 – Glow plug system................................................................................................................................................................................................................................................................................................................................................................................................................................................. 1331
1 Glow plug system................................................................................................................................................................................................................................................................................................................................................................................................................................................ 1331
1.1 Exploded view - glow plug system.......................................................................................................................................................................................................................................................................................................................................................................................................................... 1331
1.2 Removing and installing glow plug......................................................................................................................................................................................................................................................................................................................................................................................................................... 1331
1.3 Checking glow plug........................................................................................................................................................................................................................................................................................................................................................................................................................................ 1333
1.4 Removing and installing Hall sender -G40-................................................................................................................................................................................................................................................................................................................................................................................................................. 1334
1.5 Removing and installing engine speed sender -G28-......................................................................................................................................................................................................................................................................................................................................................................................................... 1335
4-cylinder_TDI_engine__2_0_ltr__4-valve_common_rail_(EA_288_Gen__I)....................................................................................................................................................................................................................................................................................................................................................................................................... 1336
00 – Technical data................................................................................................................................................................................................................................................................................................................................................................................................................................................... 1344
1 Identification.................................................................................................................................................................................................................................................................................................................................................................................................................................................. 1344
1.1 Engine identification number/engine data.................................................................................................................................................................................................................................................................................................................................................................................................................. 1344
2 Safety precautions.............................................................................................................................................................................................................................................................................................................................................................................................................................................. 1345
2.1 Safety precautions when working on the fuel system........................................................................................................................................................................................................................................................................................................................................................................................................ 1345
2.2 Safety precautions when using testers and measuring instruments during a road test........................................................................................................................................................................................................................................................................................................................................................................ 1346
2.3 Safety precautions when working on the cooling system..................................................................................................................................................................................................................................................................................................................................................................................................... 1346
2.4 Safety precautions when working on vehicles with start/stop system........................................................................................................................................................................................................................................................................................................................................................................................ 1347
2.5 Safety precautions when working on the SCR system......................................................................................................................................................................................................................................................................................................................................................................................................... 1347
2.6 Safety precautions when working on the exhaust system..................................................................................................................................................................................................................................................................................................................................................................................................... 1348
3 Repair instructions............................................................................................................................................................................................................................................................................................................................................................................................................................................. 1349
3.1 Rules for cleanliness..................................................................................................................................................................................................................................................................................................................................................................................................................................... 1349
3.2 General notes............................................................................................................................................................................................................................................................................................................................................................................................................................................. 1349
3.3 General repair instructions............................................................................................................................................................................................................................................................................................................................................................................................................................... 1350
3.4 Adapting learnt values for SCR system..................................................................................................................................................................................................................................................................................................................................................................................................................... 1351
3.5 Foreign particles in engine............................................................................................................................................................................................................................................................................................................................................................................................................................... 1351
3.6 Contact corrosion......................................................................................................................................................................................................................................................................................................................................................................................................................................... 1351
3.7 Routing and attachment of pipes, hoses and wiring......................................................................................................................................................................................................................................................................................................................................................................................................... 1351
3.8 Installing radiators and condensers....................................................................................................................................................................................................................................................................................................................................................................................................................... 1352
10 – Removing and installing engine................................................................................................................................................................................................................................................................................................................................................................................................................................... 1353
1 Removing and installing engine.................................................................................................................................................................................................................................................................................................................................................................................................................................. 1353
1.1 Removing engine........................................................................................................................................................................................................................................................................................................................................................................................................................................... 1353
1.2 Securing engine to engine and gearbox support............................................................................................................................................................................................................................................................................................................................................................................................................. 1364
1.3 Installing engine......................................................................................................................................................................................................................................................................................................................................................................................................................................... 1366
2 Assembly mountings.............................................................................................................................................................................................................................................................................................................................................................................................................................................. 1369
2.1 Exploded view - assembly mountings........................................................................................................................................................................................................................................................................................................................................................................................................................ 1369
2.2 Supporting engine in installation position................................................................................................................................................................................................................................................................................................................................................................................................................ 1370
2.3 Removing and installing engine mountings.................................................................................................................................................................................................................................................................................................................................................................................................................. 1371
2.4 Removing and installing torque reaction support and cross member.......................................................................................................................................................................................................................................................................................................................................................................................... 1372
3 Engine cover panel.............................................................................................................................................................................................................................................................................................................................................................................................................................................. 1375
3.1 Removing and installing engine cover panel................................................................................................................................................................................................................................................................................................................................................................................................................ 1375
13 – Crankshaft group................................................................................................................................................................................................................................................................................................................................................................................................................................................. 1376
1 Cylinder block (pulley end)..................................................................................................................................................................................................................................................................................................................................................................................................................................... 1376
1.1 Exploded view - cylinder block (pulley end)............................................................................................................................................................................................................................................................................................................................................................................................................... 1376
1.2 Exploded view - sealing flange (pulley end)............................................................................................................................................................................................................................................................................................................................................................................................................... 1378
1.3 Removing and installing poly V-belt....................................................................................................................................................................................................................................................................................................................................................................................................................... 1379
1.4 Removing and installing tensioner for poly V-belt......................................................................................................................................................................................................................................................................................................................................................................................................... 1381
1.5 Removing and installing vibration damper.................................................................................................................................................................................................................................................................................................................................................................................................................. 1381
1.6 Removing and installing bracket for ancillaries........................................................................................................................................................................................................................................................................................................................................................................................................... 1382
1.7 Removing and installing sealing flange (pulley end)....................................................................................................................................................................................................................................................................................................................................................................................................... 1383
2 Cylinder block (gearbox end).................................................................................................................................................................................................................................................................................................................................................................................................................................... 1386
2.1 Exploded view - cylinder block (gearbox end).............................................................................................................................................................................................................................................................................................................................................................................................................. 1386
2.2 Removing and installing drive plate....................................................................................................................................................................................................................................................................................................................................................................................................................... 1387
2.3 Removing and installing sealing flange (gearbox end)...................................................................................................................................................................................................................................................................................................................................................................................................... 1388
2.4 Renewing needle bearing in drive plate.................................................................................................................................................................................................................................................................................................................................................................................................................... 1395
3 Crankshaft...................................................................................................................................................................................................................................................................................................................................................................................................................................................... 1397
3.1 Crankshaft dimensions..................................................................................................................................................................................................................................................................................................................................................................................................................................... 1397
3.2 Measuring axial clearance of crankshaft................................................................................................................................................................................................................................................................................................................................................................................................................... 1397
4 Pistons and conrods............................................................................................................................................................................................................................................................................................................................................................................................................................................. 1398
4.1 Exploded view - pistons and conrods....................................................................................................................................................................................................................................................................................................................................................................................................................... 1398
4.2 Removing and installing pistons........................................................................................................................................................................................................................................................................................................................................................................................................................... 1401
4.3 Measuring piston projection at TDC........................................................................................................................................................................................................................................................................................................................................................................................................................ 1402
4.4 Checking pistons and cylinder bores....................................................................................................................................................................................................................................................................................................................................................................................................................... 1404
4.5 Separating parts of new conrod............................................................................................................................................................................................................................................................................................................................................................................................................................ 1405
4.6 Checking radial clearance of conrod bearings.............................................................................................................................................................................................................................................................................................................................................................................................................. 1405
15 – Cylinder head, valve gear........................................................................................................................................................................................................................................................................................................................................................................................................................................ 1407
1 Toothed belt drive.............................................................................................................................................................................................................................................................................................................................................................................................................................................. 1407
1.1 Exploded view - toothed belt cover........................................................................................................................................................................................................................................................................................................................................................................................................................ 1407
1.2 Exploded view - toothed belt.............................................................................................................................................................................................................................................................................................................................................................................................................................. 1408
1.3 Removing and installing toothed belt cover................................................................................................................................................................................................................................................................................................................................................................................................................ 1409
1.3.1 Removing and installing toothed belt cover (top).................................................................................................................................................................................................................................................................................................................................................................................................... 1409
1.3.2 Removing and installing toothed belt cover (bottom)................................................................................................................................................................................................................................................................................................................................................................................................. 1410
1.4 Detaching toothed belt from camshaft...................................................................................................................................................................................................................................................................................................................................................................................................................... 1411
1.5 Removing and installing toothed belt...................................................................................................................................................................................................................................................................................................................................................................................................................... 1421
2 Cylinder head................................................................................................................................................................................................................................................................................................................................................................................................................................................... 1432
2.1 Exploded view - cylinder head cover....................................................................................................................................................................................................................................................................................................................................................................................................................... 1432
2.2 Exploded view - cylinder head............................................................................................................................................................................................................................................................................................................................................................................................................................. 1433
2.3 Removing and installing cylinder head..................................................................................................................................................................................................................................................................................................................................................................................................................... 1435
2.4 Removing and installing cylinder head cover............................................................................................................................................................................................................................................................................................................................................................................................................... 1442
2.5 Removing and installing seals for injectors............................................................................................................................................................................................................................................................................................................................................................................................................... 1443
2.6 Removing and installing camshaft housing.................................................................................................................................................................................................................................................................................................................................................................................................................. 1445
2.7 Checking compression...................................................................................................................................................................................................................................................................................................................................................................................................................................... 1450
3 Valve gear...................................................................................................................................................................................................................................................................................................................................................................................................................................................... 1452
3.1 Exploded view - valve gear................................................................................................................................................................................................................................................................................................................................................................................................................................ 1452
3.2 Removing and installing camshaft oil seal................................................................................................................................................................................................................................................................................................................................................................................................................. 1455
3.3 Removing and installing camshaft control valve 1 -N205-................................................................................................................................................................................................................................................................................................................................................................................................... 1459
3.4 Removing and installing camshaft adjuster................................................................................................................................................................................................................................................................................................................................................................................................................. 1460
3.5 Removing and installing control valve from camshaft control valve 1 -N205-................................................................................................................................................................................................................................................................................................................................................................................ 1464
3.6 Checking hydraulic compensation elements.................................................................................................................................................................................................................................................................................................................................................................................................................. 1467
3.7 Removing and installing valve stem oil seals.............................................................................................................................................................................................................................................................................................................................................................................................................. 1468
3.7.1 Removing and installing valve stem oil seals (cylinder head installed).............................................................................................................................................................................................................................................................................................................................................................................. 1468
3.7.2 Removing and installing valve stem oil seals (cylinder head removed)................................................................................................................................................................................................................................................................................................................................................................................ 1472
4 Inlet and exhaust valves........................................................................................................................................................................................................................................................................................................................................................................................................................................ 1476
4.1 Checking valve guides..................................................................................................................................................................................................................................................................................................................................................................................................................................... 1476
4.2 Checking valves........................................................................................................................................................................................................................................................................................................................................................................................................................................... 1477
4.3 Valve dimensions.......................................................................................................................................................................................................................................................................................................................................................................................................................................... 1477
17 – Lubrication...................................................................................................................................................................................................................................................................................................................................................................................................................................................... 1478
1 Sump/oil pump................................................................................................................................................................................................................................................................................................................................................................................................................................................... 1478
1.1 Exploded view - sump/oil pump............................................................................................................................................................................................................................................................................................................................................................................................................................. 1478
1.2 Engine oil................................................................................................................................................................................................................................................................................................................................................................................................................................................ 1480
1.3 Removing and installing sump.............................................................................................................................................................................................................................................................................................................................................................................................................................. 1481
1.4 Removing and installing oil pump.......................................................................................................................................................................................................................................................................................................................................................................................................................... 1485
1.5 Removing and installing oil level and oil temperature sender -G266-....................................................................................................................................................................................................................................................................................................................................................................................... 1485
2 Engine oil cooler............................................................................................................................................................................................................................................................................................................................................................................................................................................... 1487
3 Oil filter/oil pressure switches................................................................................................................................................................................................................................................................................................................................................................................................................................ 1488
3.1 Exploded view - oil filter housing/oil pressure switches.................................................................................................................................................................................................................................................................................................................................................................................................. 1488
3.2 Removing and installing oil pressure switch -F22-......................................................................................................................................................................................................................................................................................................................................................................................................... 1489
3.3 Removing and installing oil pressure switch for reduced oil pressure -F378-............................................................................................................................................................................................................................................................................................................................................................................... 1490
3.4 Removing and installing oil filter housing................................................................................................................................................................................................................................................................................................................................................................................................................ 1491
3.5 Removing and installing valve for oil pressure control -N428-............................................................................................................................................................................................................................................................................................................................................................................................. 1493
3.6 Checking oil pressure..................................................................................................................................................................................................................................................................................................................................................................................................................................... 1494
19 – Cooling.......................................................................................................................................................................................................................................................................................................................................................................................................................................................... 1496
1 Cooling system/coolant.......................................................................................................................................................................................................................................................................................................................................................................................................................................... 1496
1.1 Connection diagram - coolant hoses........................................................................................................................................................................................................................................................................................................................................................................................................................ 1496
1.1.1 Connection diagram - coolant hoses, vehicles without auxiliary heater............................................................................................................................................................................................................................................................................................................................................................................... 1496
1.1.2 Connection diagram - coolant hoses, vehicles with auxiliary heater.................................................................................................................................................................................................................................................................................................................................................................................. 1498
1.2 Draining and filling cooling system....................................................................................................................................................................................................................................................................................................................................................................................................................... 1499
1.3 Checking cooling system for leaks......................................................................................................................................................................................................................................................................................................................................................................................................................... 1508
2 Coolant pump/thermostat assembly................................................................................................................................................................................................................................................................................................................................................................................................................................ 1510
2.1 Exploded view - coolant pump/thermostat................................................................................................................................................................................................................................................................................................................................................................................................................... 1510
2.2 Exploded view - electric coolant pump..................................................................................................................................................................................................................................................................................................................................................................................................................... 1512
2.3 Exploded view - coolant temperature senders............................................................................................................................................................................................................................................................................................................................................................................................................... 1513
2.4 Removing and installing electric coolant pump............................................................................................................................................................................................................................................................................................................................................................................................................. 1513
2.4.1 Removing and installing charge air cooling pump -V188-.............................................................................................................................................................................................................................................................................................................................................................................................. 1513
2.4.2 Removing and installing auxiliary pump for heating -V488-........................................................................................................................................................................................................................................................................................................................................................................................... 1515
2.5 Removing and installing coolant pump...................................................................................................................................................................................................................................................................................................................................................................................................................... 1517
2.6 Checking thermostat....................................................................................................................................................................................................................................................................................................................................................................................................................................... 1517
2.7 Removing and installing coolant valve for cylinder head -N489-............................................................................................................................................................................................................................................................................................................................................................................................ 1518
2.8 Removing and installing coolant temperature sender -G62-.................................................................................................................................................................................................................................................................................................................................................................................................. 1518
3 Coolant pipes................................................................................................................................................................................................................................................................................................................................................................................................................................................... 1520
3.1 Exploded view - coolant pipes............................................................................................................................................................................................................................................................................................................................................................................................................................. 1520
3.2 Removing and installing coolant pipes..................................................................................................................................................................................................................................................................................................................................................................................................................... 1521
3.2.1 Removing and installing coolant pipe (left-side).................................................................................................................................................................................................................................................................................................................................................................................................... 1521
3.2.2 Removing and installing coolant pipes (rear left)................................................................................................................................................................................................................................................................................................................................................................................................... 1522
3.2.3 Removing and installing coolant pipe (top left)..................................................................................................................................................................................................................................................................................................................................................................................................... 1524
3.2.4 Removing and installing coolant pipes (bottom left)................................................................................................................................................................................................................................................................................................................................................................................................. 1524
3.2.5 Removing and installing coolant pipe (right-side)................................................................................................................................................................................................................................................................................................................................................................................................... 1526
3.2.6 Removing and installing coolant pipe (rear right)................................................................................................................................................................................................................................................................................................................................................................................................... 1527
3.2.7 Removing and installing coolant pipe (rear)......................................................................................................................................................................................................................................................................................................................................................................................................... 1530
4 Radiators/radiator fans......................................................................................................................................................................................................................................................................................................................................................................................................................................... 1533
4.1 Exploded view - radiators/radiator fans................................................................................................................................................................................................................................................................................................................................................................................................................... 1533
4.2 Removing and installing radiator.......................................................................................................................................................................................................................................................................................................................................................................................................................... 1535
4.3 Removing and installing water radiator for charge air cooling circuit..................................................................................................................................................................................................................................................................................................................................................................................... 1539
4.4 Removing and installing radiator cowl..................................................................................................................................................................................................................................................................................................................................................................................................................... 1542
4.5 Removing and installing radiator fan -V7-................................................................................................................................................................................................................................................................................................................................................................................................................. 1546
4.6 Removing and installing radiator fan 2 -V177-............................................................................................................................................................................................................................................................................................................................................................................................................. 1546
4.7 Removing and installing radiator fan control unit......................................................................................................................................................................................................................................................................................................................................................................................................... 1546
21 – Turbocharging/supercharging...................................................................................................................................................................................................................................................................................................................................................................................................................................... 1549
1 Turbocharger.................................................................................................................................................................................................................................................................................................................................................................................................................................................... 1549
1.1 Exploded view - turbocharger.............................................................................................................................................................................................................................................................................................................................................................................................................................. 1549
1.2 Removing and installing turbocharger...................................................................................................................................................................................................................................................................................................................................................................................................................... 1551
1.3 Renewing vacuum unit for turbocharger..................................................................................................................................................................................................................................................................................................................................................................................................................... 1555
2 Charge air system............................................................................................................................................................................................................................................................................................................................................................................................................................................... 1562
2.1 Exploded view - charge air system......................................................................................................................................................................................................................................................................................................................................................................................................................... 1562
2.2 Removing and installing charge pressure sender -G31-...................................................................................................................................................................................................................................................................................................................................................................................................... 1564
2.3 Removing and installing charge air temperature sender..................................................................................................................................................................................................................................................................................................................................................................................................... 1564
2.4 Checking charge air system for leaks...................................................................................................................................................................................................................................................................................................................................................................................................................... 1565
23 – Mixture preparation - injection.................................................................................................................................................................................................................................................................................................................................................................................................................................. 1570
1 Injection system................................................................................................................................................................................................................................................................................................................................................................................................................................................ 1570
1.1 Overview of fitting locations - injection system.......................................................................................................................................................................................................................................................................................................................................................................................................... 1570
1.2 Overview - fuel system.................................................................................................................................................................................................................................................................................................................................................................................................................................... 1575
1.3 Filling and bleeding fuel system.......................................................................................................................................................................................................................................................................................................................................................................................................................... 1576
1.4 Checking fuel system for leaks............................................................................................................................................................................................................................................................................................................................................................................................................................ 1577
2 Vacuum system................................................................................................................................................................................................................................................................................................................................................................................................................................................... 1578
2.1 Connection diagram - vacuum system........................................................................................................................................................................................................................................................................................................................................................................................................................ 1578
2.2 Checking vacuum system.................................................................................................................................................................................................................................................................................................................................................................................................................................... 1578
3 Air cleaner..................................................................................................................................................................................................................................................................................................................................................................................................................................................... 1580
3.1 Exploded view - air cleaner housing....................................................................................................................................................................................................................................................................................................................................................................................................................... 1580
3.2 Removing and installing air cleaner housing............................................................................................................................................................................................................................................................................................................................................................................................................... 1581
4 Intake manifold................................................................................................................................................................................................................................................................................................................................................................................................................................................. 1583
4.1 Exploded view - intake manifold........................................................................................................................................................................................................................................................................................................................................................................................................................... 1583
4.2 Removing and installing throttle valve module -J338-...................................................................................................................................................................................................................................................................................................................................................................................................... 1585
4.3 Removing and installing intake manifold................................................................................................................................................................................................................................................................................................................................................................................................................... 1587
5 Injectors/high-pressure reservoir (rail)........................................................................................................................................................................................................................................................................................................................................................................................................................ 1591
5.1 Exploded view - injectors................................................................................................................................................................................................................................................................................................................................................................................................................................. 1591
5.2 Exploded view - high-pressure reservoir (rail)............................................................................................................................................................................................................................................................................................................................................................................................................ 1593
5.3 Checking injectors........................................................................................................................................................................................................................................................................................................................................................................................................................................ 1594
5.4 Performing adaption of correction values for injectors.................................................................................................................................................................................................................................................................................................................................................................................................... 1594
5.5 Checking for injectors sticking open...................................................................................................................................................................................................................................................................................................................................................................................................................... 1595
5.6 Checking return flow rate of injectors with engine running................................................................................................................................................................................................................................................................................................................................................................................................ 1597
5.7 Checking return flow rate of injectors at starter cranking speed.......................................................................................................................................................................................................................................................................................................................................................................................... 1600
5.8 Removing and installing injectors......................................................................................................................................................................................................................................................................................................................................................................................................................... 1601
5.9 Removing and installing high-pressure pipes............................................................................................................................................................................................................................................................................................................................................................................................................... 1605
5.9.1 Removing high-pressure pipe between high-pressure reservoir (rail) and high-pressure pump........................................................................................................................................................................................................................................................................................................................................................... 1605
5.9.2 Installing high-pressure pipe....................................................................................................................................................................................................................................................................................................................................................................................................................... 1606
5.10 Removing and installing high-pressure reservoir (rail)................................................................................................................................................................................................................................................................................................................................................................................................... 1608
6 High-pressure pump.............................................................................................................................................................................................................................................................................................................................................................................................................................................. 1610
6.1 Exploded view - high-pressure pump........................................................................................................................................................................................................................................................................................................................................................................................................................ 1610
6.2 Removing and installing high-pressure pump................................................................................................................................................................................................................................................................................................................................................................................................................ 1611
7 Senders and sensors............................................................................................................................................................................................................................................................................................................................................................................................................................................. 1614
7.1 Removing and installing fuel temperature sender -G81-..................................................................................................................................................................................................................................................................................................................................................................................................... 1614
7.2 Removing and installing air mass meter -G70-.............................................................................................................................................................................................................................................................................................................................................................................................................. 1614
7.3 Checking fuel pressure regulating valve -N276-............................................................................................................................................................................................................................................................................................................................................................................................................ 1615
7.4 Removing and installing fuel pressure regulating valve -N276-............................................................................................................................................................................................................................................................................................................................................................................................. 1617
7.5 Removing and installing fuel pressure sender -G247-....................................................................................................................................................................................................................................................................................................................................................................................................... 1619
8 Lambda probe.................................................................................................................................................................................................................................................................................................................................................................................................................................................... 1622
8.1 Exploded view - Lambda probe.............................................................................................................................................................................................................................................................................................................................................................................................................................. 1622
8.2 Removing and installing Lambda probe...................................................................................................................................................................................................................................................................................................................................................................................................................... 1623
8.3 Removing and installing NOx sender........................................................................................................................................................................................................................................................................................................................................................................................................................ 1624
9 Engine control unit............................................................................................................................................................................................................................................................................................................................................................................................................................................. 1626
9.1 Removing and installing engine control unit -J623-........................................................................................................................................................................................................................................................................................................................................................................................................ 1626
9.1.1 Removing and installing engine control unit -J623- without protective housing....................................................................................................................................................................................................................................................................................................................................................................... 1626
9.1.2 Removing and installing engine control unit -J623- with protective housing.......................................................................................................................................................................................................................................................................................................................................................................... 1628
26 – Exhaust system................................................................................................................................................................................................................................................................................................................................................................................................................................................... 1632
1 Exhaust pipes/silencers......................................................................................................................................................................................................................................................................................................................................................................................................................................... 1632
1.1 Exploded view - silencers................................................................................................................................................................................................................................................................................................................................................................................................................................. 1632
1.2 Removing and installing front exhaust pipe................................................................................................................................................................................................................................................................................................................................................................................................................ 1635
1.3 Separating exhaust pipes/silencers........................................................................................................................................................................................................................................................................................................................................................................................................................ 1638
1.4 Removing and installing silencers......................................................................................................................................................................................................................................................................................................................................................................................................................... 1639
1.5 Stress-free alignment of exhaust system................................................................................................................................................................................................................................................................................................................................................................................................................... 1639
1.6 Checking exhaust system for leaks......................................................................................................................................................................................................................................................................................................................................................................................................................... 1641
2 Emission control system......................................................................................................................................................................................................................................................................................................................................................................................................................................... 1642
2.1 Exploded view - emission control system................................................................................................................................................................................................................................................................................................................................................................................................................... 1642
2.2 Removing and installing catalytic converter............................................................................................................................................................................................................................................................................................................................................................................................................... 1644
2.3 Removing and installing emission control module........................................................................................................................................................................................................................................................................................................................................................................................................... 1646
2.4 Removing and installing exhaust gas pressure sensor 1 -G450-.............................................................................................................................................................................................................................................................................................................................................................................................. 1655
2.5 Removing and installing pressure differential sender -G505-............................................................................................................................................................................................................................................................................................................................................................................................... 1656
2.6 Removing and installing exhaust flap control unit -J883-.................................................................................................................................................................................................................................................................................................................................................................................................. 1658
3 SCR (selective catalytic reduction) system...................................................................................................................................................................................................................................................................................................................................................................................................................... 1659
3.1 Exploded view - reducing agent tank....................................................................................................................................................................................................................................................................................................................................................................................................................... 1659
3.2 Exploded view - reducing agent supply line................................................................................................................................................................................................................................................................................................................................................................................................................ 1662
3.3 Exploded view - delivery unit for reducing agent.......................................................................................................................................................................................................................................................................................................................................................................................................... 1663
3.4 Exploded view - control unit for reducing agent metering system -J880-.................................................................................................................................................................................................................................................................................................................................................................................... 1664
3.5 Draining reducing agent tank.............................................................................................................................................................................................................................................................................................................................................................................................................................. 1665
3.5.1 Draining reducing agent tank - active tank.......................................................................................................................................................................................................................................................................................................................................................................................................... 1665
3.5.2 Draining reducing agent tank - passive tank......................................................................................................................................................................................................................................................................................................................................................................................................... 1666
3.6 Removing and installing delivery unit for reducing agent.................................................................................................................................................................................................................................................................................................................................................................................................. 1667
3.7 Removing and installing injector for reducing agent -N474-................................................................................................................................................................................................................................................................................................................................................................................................ 1670
3.8 Removing and installing active tank for reducing agent.................................................................................................................................................................................................................................................................................................................................................................................................... 1672
3.9 Removing and installing passive tank for reducing agent................................................................................................................................................................................................................................................................................................................................................................................................... 1674
3.10 Removing and installing transfer pump for reducing agent -V436-.......................................................................................................................................................................................................................................................................................................................................................................................... 1676
3.11 Removing and installing control unit for reducing agent metering system -J880-........................................................................................................................................................................................................................................................................................................................................................................... 1678
4 Exhaust gas temperature control................................................................................................................................................................................................................................................................................................................................................................................................................................. 1680
4.1 Exploded view - exhaust gas temperature control........................................................................................................................................................................................................................................................................................................................................................................................................... 1680
4.2 Removing and installing exhaust gas temperature sender.................................................................................................................................................................................................................................................................................................................................................................................................... 1681
4.2.1 Removing and installing exhaust gas temperature sender 1 -G235-..................................................................................................................................................................................................................................................................................................................................................................................... 1681
4.2.2 Removing and installing exhaust gas temperature sender 2 -G448-..................................................................................................................................................................................................................................................................................................................................................................................... 1682
4.2.3 Removing and installing exhaust gas temperature sender 3 -G495-..................................................................................................................................................................................................................................................................................................................................................................................... 1684
4.2.4 Removing and installing exhaust gas temperature sender 4 -G648-..................................................................................................................................................................................................................................................................................................................................................................................... 1685
5 Exhaust gas recirculation....................................................................................................................................................................................................................................................................................................................................................................................................................................... 1687
5.1 Exploded view - exhaust gas recirculation system.......................................................................................................................................................................................................................................................................................................................................................................................................... 1687
5.2 Removing and installing exhaust gas recirculation control motor -V338-.................................................................................................................................................................................................................................................................................................................................................................................... 1689
5.3 Removing and installing exhaust gas recirculation control motor 2 -V339-.................................................................................................................................................................................................................................................................................................................................................................................. 1689
5.4 Removing and installing exhaust gas recirculation cooler.................................................................................................................................................................................................................................................................................................................................................................................................. 1692
28 – Glow plug system................................................................................................................................................................................................................................................................................................................................................................................................................................................. 1694
1 Glow plug system................................................................................................................................................................................................................................................................................................................................................................................................................................................ 1694
1.1 Exploded view - glow plug system.......................................................................................................................................................................................................................................................................................................................................................................................................................... 1694
1.2 Removing and installing glow plug......................................................................................................................................................................................................................................................................................................................................................................................................................... 1695
1.3 Removing and installing automatic glow period control unit -J179-......................................................................................................................................................................................................................................................................................................................................................................................... 1697
1.4 Removing and installing Hall sender -G40-................................................................................................................................................................................................................................................................................................................................................................................................................. 1697
1.5 Removing and installing engine speed sender -G28-......................................................................................................................................................................................................................................................................................................................................................................................................... 1698
6-cylinder_direct_injection_engine_(evo)_with_supercharger_(3_0_ltr__4-valve_TFSI)........................................................................................................................................................................................................................................................................................................................................................................................ 1700
00 – Technical data................................................................................................................................................................................................................................................................................................................................................................................................................................................... 1708
1 Identification.................................................................................................................................................................................................................................................................................................................................................................................................................................................. 1708
1.1 Engine identification number/engine data.................................................................................................................................................................................................................................................................................................................................................................................................................. 1708
2 Safety precautions.............................................................................................................................................................................................................................................................................................................................................................................................................................................. 1709
2.1 Safety precautions when working on the fuel supply system................................................................................................................................................................................................................................................................................................................................................................................................. 1709
2.2 Safety precautions when working on vehicles with start/stop system........................................................................................................................................................................................................................................................................................................................................................................................ 1709
2.3 Safety precautions when using testers and measuring instruments during a road test........................................................................................................................................................................................................................................................................................................................................................................ 1710
2.4 Safety precautions when working on the cooling system..................................................................................................................................................................................................................................................................................................................................................................................................... 1710
2.5 Safety precautions when working on the ignition system.................................................................................................................................................................................................................................................................................................................................................................................................... 1710
2.6 Safety precautions when working on the subframe........................................................................................................................................................................................................................................................................................................................................................................................................... 1711
2.7 Safety precautions when working on the exhaust system..................................................................................................................................................................................................................................................................................................................................................................................................... 1711
3 Repair instructions............................................................................................................................................................................................................................................................................................................................................................................................................................................. 1712
3.1 Rules for cleanliness..................................................................................................................................................................................................................................................................................................................................................................................................................................... 1712
3.2 Foreign particles in engine............................................................................................................................................................................................................................................................................................................................................................................................................................... 1712
3.3 Contact corrosion......................................................................................................................................................................................................................................................................................................................................................................................................................................... 1712
3.4 Routing and attachment of pipes, hoses and wiring......................................................................................................................................................................................................................................................................................................................................................................................................... 1713
3.5 Installing radiators and condensers....................................................................................................................................................................................................................................................................................................................................................................................................................... 1713
10 – Removing and installing engine................................................................................................................................................................................................................................................................................................................................................................................................................................... 1714
1 Removing and installing engine.................................................................................................................................................................................................................................................................................................................................................................................................................................. 1714
1.1 Removing engine........................................................................................................................................................................................................................................................................................................................................................................................................................................... 1714
1.2 Separating engine and gearbox............................................................................................................................................................................................................................................................................................................................................................................................................................. 1731
1.3 Securing engine to engine and gearbox support............................................................................................................................................................................................................................................................................................................................................................................................................. 1737
1.4 Installing engine......................................................................................................................................................................................................................................................................................................................................................................................................................................... 1739
2 Assembly mountings.............................................................................................................................................................................................................................................................................................................................................................................................................................................. 1747
2.1 Exploded view - assembly mountings........................................................................................................................................................................................................................................................................................................................................................................................................................ 1747
2.2 Supporting engine in installation position................................................................................................................................................................................................................................................................................................................................................................................................................ 1748
2.3 Removing and installing engine mountings.................................................................................................................................................................................................................................................................................................................................................................................................................. 1749
2.3.1 Removing and installing engine mounting (left-side)................................................................................................................................................................................................................................................................................................................................................................................................. 1749
2.3.2 Removing and installing engine mounting (right-side)................................................................................................................................................................................................................................................................................................................................................................................................ 1750
2.4 Removing and installing gearbox mounting.................................................................................................................................................................................................................................................................................................................................................................................................................. 1752
2.4.1 Removing and installing gearbox support with gearbox mounting....................................................................................................................................................................................................................................................................................................................................................................................... 1752
2.4.2 Removing and installing gearbox mounting............................................................................................................................................................................................................................................................................................................................................................................................................ 1753
3 Engine cover panel.............................................................................................................................................................................................................................................................................................................................................................................................................................................. 1754
3.1 Removing and installing engine cover panel................................................................................................................................................................................................................................................................................................................................................................................................................ 1754
13 – Crankshaft group................................................................................................................................................................................................................................................................................................................................................................................................................................................. 1755
1 Cylinder block (pulley end)..................................................................................................................................................................................................................................................................................................................................................................................................................................... 1755
1.1 Exploded view - poly V-belt drive......................................................................................................................................................................................................................................................................................................................................................................................................................... 1755
1.1.1 Exploded view - poly V-belt drive, poly V-belt for supercharger..................................................................................................................................................................................................................................................................................................................................................................................... 1755
1.1.2 Exploded view - poly V-belt drive, poly V-belt for ancillaries...................................................................................................................................................................................................................................................................................................................................................................................... 1756
1.2 Removing and installing poly V-belts...................................................................................................................................................................................................................................................................................................................................................................................................................... 1758
1.2.1 Removing and installing poly V-belt for supercharger................................................................................................................................................................................................................................................................................................................................................................................................ 1758
1.2.2 Removing and installing poly V-belt for ancillaries................................................................................................................................................................................................................................................................................................................................................................................................. 1759
1.3 Removing and installing tensioner for poly V-belt......................................................................................................................................................................................................................................................................................................................................................................................................... 1761
1.3.1 Removing and installing tensioner for poly V-belt for supercharger.................................................................................................................................................................................................................................................................................................................................................................................. 1761
1.3.2 Removing and installing tensioner for poly V-belt for ancillaries................................................................................................................................................................................................................................................................................................................................................................................... 1762
1.4 Removing and installing vibration damper.................................................................................................................................................................................................................................................................................................................................................................................................................. 1763
1.5 Removing and installing sealing flange (pulley end)....................................................................................................................................................................................................................................................................................................................................................................................................... 1764
2 Cylinder block (gearbox end).................................................................................................................................................................................................................................................................................................................................................................................................................................... 1767
2.1 Exploded view - cylinder block (gearbox end).............................................................................................................................................................................................................................................................................................................................................................................................................. 1767
2.2 Removing and installing drive plate....................................................................................................................................................................................................................................................................................................................................................................................................................... 1767
2.3 Renewing crankshaft oil seal (gearbox end)................................................................................................................................................................................................................................................................................................................................................................................................................ 1768
3 Crankshaft...................................................................................................................................................................................................................................................................................................................................................................................................................................................... 1771
3.1 Exploded view - crankshaft................................................................................................................................................................................................................................................................................................................................................................................................................................ 1771
3.2 Crankshaft dimensions..................................................................................................................................................................................................................................................................................................................................................................................................................................... 1774
3.3 Measuring axial clearance of crankshaft................................................................................................................................................................................................................................................................................................................................................................................................................... 1774
3.4 Measuring radial clearance of crankshaft.................................................................................................................................................................................................................................................................................................................................................................................................................. 1775
3.5 Removing and installing sender wheel...................................................................................................................................................................................................................................................................................................................................................................................................................... 1776
3.6 Checking sender wheel..................................................................................................................................................................................................................................................................................................................................................................................................................................... 1776
4 Balance shaft................................................................................................................................................................................................................................................................................................................................................................................................................................................... 1778
4.1 Exploded view - balance shaft............................................................................................................................................................................................................................................................................................................................................................................................................................. 1778
4.2 Removing and installing balance shaft..................................................................................................................................................................................................................................................................................................................................................................................................................... 1778
5 Pistons and conrods............................................................................................................................................................................................................................................................................................................................................................................................................................................. 1781
5.1 Exploded view - pistons and conrods....................................................................................................................................................................................................................................................................................................................................................................................................................... 1781
5.2 Removing and installing pistons........................................................................................................................................................................................................................................................................................................................................................................................................................... 1783
5.3 Checking pistons and cylinder bores....................................................................................................................................................................................................................................................................................................................................................................................................................... 1784
5.4 Checking radial clearance of conrod bearings.............................................................................................................................................................................................................................................................................................................................................................................................................. 1785
15 – Cylinder head, valve gear........................................................................................................................................................................................................................................................................................................................................................................................................................................ 1786
1 Timing chain cover.............................................................................................................................................................................................................................................................................................................................................................................................................................................. 1786
1.1 Exploded view - timing chain cover........................................................................................................................................................................................................................................................................................................................................................................................................................ 1786
1.2 Removing and installing timing chain cover................................................................................................................................................................................................................................................................................................................................................................................................................ 1789
1.2.1 Removing and installing timing chain cover (left-side).............................................................................................................................................................................................................................................................................................................................................................................................. 1789
1.2.2 Removing and installing timing chain cover (right-side)............................................................................................................................................................................................................................................................................................................................................................................................. 1791
1.2.3 Removing and installing timing chain cover (bottom)................................................................................................................................................................................................................................................................................................................................................................................................. 1794
2 Chain drive..................................................................................................................................................................................................................................................................................................................................................................................................................................................... 1800
2.1 Exploded view - camshaft timing chains.................................................................................................................................................................................................................................................................................................................................................................................................................... 1800
2.2 Exploded view - drive chain for valve gear................................................................................................................................................................................................................................................................................................................................................................................................................ 1802
2.3 Exploded view - drive chain for oil pump.................................................................................................................................................................................................................................................................................................................................................................................................................. 1804
2.4 Removing camshaft timing chain from camshafts............................................................................................................................................................................................................................................................................................................................................................................................................. 1804
2.5 Removing and installing camshaft timing chain............................................................................................................................................................................................................................................................................................................................................................................................................. 1814
2.6 Removing and installing drive chain for valve gear........................................................................................................................................................................................................................................................................................................................................................................................................ 1816
2.7 Removing and installing drive chain for oil pump.......................................................................................................................................................................................................................................................................................................................................................................................................... 1819
3 Cylinder head................................................................................................................................................................................................................................................................................................................................................................................................................................................... 1820
3.1 Exploded view - cylinder head............................................................................................................................................................................................................................................................................................................................................................................................................................. 1820
3.2 Removing and installing cylinder head..................................................................................................................................................................................................................................................................................................................................................................................................................... 1822
3.2.1 Removing and installing cylinder head, bank 1 (right-side).......................................................................................................................................................................................................................................................................................................................................................................................... 1822
3.2.2 Removing cylinder head, bank 2 (left-side).......................................................................................................................................................................................................................................................................................................................................................................................................... 1824
3.2.3 Installing cylinder head............................................................................................................................................................................................................................................................................................................................................................................................................................ 1827
3.3 Removing and installing cylinder head cover............................................................................................................................................................................................................................................................................................................................................................................................................... 1829
3.4 Checking compression...................................................................................................................................................................................................................................................................................................................................................................................................................................... 1831
4 Valve gear...................................................................................................................................................................................................................................................................................................................................................................................................................................................... 1833
4.1 Exploded view - valve gear................................................................................................................................................................................................................................................................................................................................................................................................................................ 1833
4.2 Measuring axial clearance of camshaft..................................................................................................................................................................................................................................................................................................................................................................................................................... 1836
4.3 Measuring radial clearance of camshaft.................................................................................................................................................................................................................................................................................................................................................................................................................... 1837
4.4 Removing and installing camshaft.......................................................................................................................................................................................................................................................................................................................................................................................................................... 1838
4.5 Removing and installing camshaft control valves........................................................................................................................................................................................................................................................................................................................................................................................................... 1844
4.6 Checking hydraulic valve compensation elements............................................................................................................................................................................................................................................................................................................................................................................................................ 1845
4.7 Removing and installing valve stem oil seals.............................................................................................................................................................................................................................................................................................................................................................................................................. 1847
4.7.1 Removing and installing valve stem oil seals (cylinder head installed).............................................................................................................................................................................................................................................................................................................................................................................. 1847
4.7.2 Removing and installing valve stem oil seals (cylinder head removed)................................................................................................................................................................................................................................................................................................................................................................................ 1850
5 Inlet and exhaust valves........................................................................................................................................................................................................................................................................................................................................................................................................................................ 1854
5.1 Checking valve guides..................................................................................................................................................................................................................................................................................................................................................................................................................................... 1854
5.2 Checking valves........................................................................................................................................................................................................................................................................................................................................................................................................................................... 1855
5.3 Valve dimensions.......................................................................................................................................................................................................................................................................................................................................................................................................................................... 1855
17 – Lubrication...................................................................................................................................................................................................................................................................................................................................................................................................................................................... 1856
1 Sump/oil pump................................................................................................................................................................................................................................................................................................................................................................................................................................................... 1856
1.1 Exploded view - sump/oil pump............................................................................................................................................................................................................................................................................................................................................................................................................................. 1856
1.2 Engine oil................................................................................................................................................................................................................................................................................................................................................................................................................................................ 1859
1.3 Removing and installing sump (bottom section)............................................................................................................................................................................................................................................................................................................................................................................................................. 1859
1.4 Removing and installing sump (top section)................................................................................................................................................................................................................................................................................................................................................................................................................ 1861
1.5 Removing and installing oil pump.......................................................................................................................................................................................................................................................................................................................................................................................................................... 1864
1.6 Removing and installing oil level and oil temperature sender -G266-....................................................................................................................................................................................................................................................................................................................................................................................... 1865
2 Engine oil cooler............................................................................................................................................................................................................................................................................................................................................................................................................................................... 1866
2.1 Exploded view - engine oil cooler......................................................................................................................................................................................................................................................................................................................................................................................................................... 1866
2.2 Removing and installing engine oil cooler................................................................................................................................................................................................................................................................................................................................................................................................................. 1866
3 Crankcase breather.............................................................................................................................................................................................................................................................................................................................................................................................................................................. 1869
3.1 Exploded view - crankcase breather system................................................................................................................................................................................................................................................................................................................................................................................................................. 1869
3.2 Removing and installing oil separator..................................................................................................................................................................................................................................................................................................................................................................................................................... 1870
3.3 Removing and installing hose for crankcase breather system................................................................................................................................................................................................................................................................................................................................................................................................ 1871
4 Oil filter/oil pressure switches................................................................................................................................................................................................................................................................................................................................................................................................................................ 1873
4.1 Exploded view - oil filter................................................................................................................................................................................................................................................................................................................................................................................................................................ 1873
4.2 Exploded view - oil pressure switches/oil pressure control................................................................................................................................................................................................................................................................................................................................................................................................ 1874
4.3 Removing and installing oil pressure switch -F22-......................................................................................................................................................................................................................................................................................................................................................................................................... 1874
4.4 Removing and installing oil pressure switch for reduced oil pressure -F378-............................................................................................................................................................................................................................................................................................................................................................................... 1875
4.5 Checking oil pressure..................................................................................................................................................................................................................................................................................................................................................................................................................................... 1876
4.6 Removing and installing valve for oil pressure control -N428-............................................................................................................................................................................................................................................................................................................................................................................................. 1877
19 – Cooling.......................................................................................................................................................................................................................................................................................................................................................................................................................................................... 1879
1 Cooling system/coolant.......................................................................................................................................................................................................................................................................................................................................................................................................................................... 1879
1.1 Connection diagram - coolant hoses........................................................................................................................................................................................................................................................................................................................................................................................................................ 1879
1.1.1 Connection diagram - coolant hoses, vehicles without auxiliary heater............................................................................................................................................................................................................................................................................................................................................................................... 1879
1.1.2 Connection diagram - coolant hoses, vehicles with auxiliary heater.................................................................................................................................................................................................................................................................................................................................................................................. 1881
1.2 Checking cooling system for leaks......................................................................................................................................................................................................................................................................................................................................................................................................................... 1882
1.3 Draining and filling cooling system....................................................................................................................................................................................................................................................................................................................................................................................................................... 1883
2 Coolant pump/thermostat assembly................................................................................................................................................................................................................................................................................................................................................................................................................................ 1890
2.1 Exploded view - coolant pump and thermostat............................................................................................................................................................................................................................................................................................................................................................................................................... 1890
2.2 Exploded view - electric coolant pump..................................................................................................................................................................................................................................................................................................................................................................................................................... 1891
2.3 Exploded view - coolant temperature senders............................................................................................................................................................................................................................................................................................................................................................................................................... 1892
2.4 Removing and installing electric coolant pump............................................................................................................................................................................................................................................................................................................................................................................................................. 1892
2.4.1 Removing and installing coolant circulation pump -V50-.............................................................................................................................................................................................................................................................................................................................................................................................. 1892
2.4.2 Removing and installing charge air cooling pump -V188-.............................................................................................................................................................................................................................................................................................................................................................................................. 1894
2.5 Removing and installing coolant pump...................................................................................................................................................................................................................................................................................................................................................................................................................... 1895
2.6 Removing and installing thermostat........................................................................................................................................................................................................................................................................................................................................................................................................................ 1897
2.7 Removing and installing coolant temperature sender -G62-.................................................................................................................................................................................................................................................................................................................................................................................................. 1898
2.8 Removing and installing temperature sender for engine temperature regulation -G694-....................................................................................................................................................................................................................................................................................................................................................................... 1899
3 Coolant pipes................................................................................................................................................................................................................................................................................................................................................................................................................................................... 1901
3.1 Exploded view - coolant pipes............................................................................................................................................................................................................................................................................................................................................................................................................................. 1901
3.2 Removing and installing coolant pipes..................................................................................................................................................................................................................................................................................................................................................................................................................... 1902
3.2.1 Removing and installing coolant pipe (front left)................................................................................................................................................................................................................................................................................................................................................................................................... 1902
3.2.2 Removing and installing coolant pipes (front left).................................................................................................................................................................................................................................................................................................................................................................................................. 1903
3.2.3 Removing and installing coolant pipe (front right).................................................................................................................................................................................................................................................................................................................................................................................................. 1905
3.2.4 Removing and installing coolant pipe (left-side).................................................................................................................................................................................................................................................................................................................................................................................................... 1907
3.2.5 Removing and installing coolant pipe (top).......................................................................................................................................................................................................................................................................................................................................................................................................... 1908
3.2.6 Removing and installing coolant pipes on supercharger............................................................................................................................................................................................................................................................................................................................................................................................... 1909
4 Radiator/radiator fans.......................................................................................................................................................................................................................................................................................................................................................................................................................................... 1912
4.1 Exploded view - radiator/radiator fans.................................................................................................................................................................................................................................................................................................................................................................................................................... 1912
4.2 Removing and installing radiator.......................................................................................................................................................................................................................................................................................................................................................................................................................... 1914
4.3 Removing and installing water radiator for charge air cooling circuit..................................................................................................................................................................................................................................................................................................................................................................................... 1918
4.4 Removing and installing radiator cowl..................................................................................................................................................................................................................................................................................................................................................................................................................... 1920
4.5 Removing and installing radiator fan -V7-................................................................................................................................................................................................................................................................................................................................................................................................................. 1925
21 – Turbocharging/supercharging...................................................................................................................................................................................................................................................................................................................................................................................................................................... 1927
1 Supercharger.................................................................................................................................................................................................................................................................................................................................................................................................................................................... 1927
1.1 Exploded view - supercharger.............................................................................................................................................................................................................................................................................................................................................................................................................................. 1927
1.2 Exploded view - magnetic clutch........................................................................................................................................................................................................................................................................................................................................................................................................................... 1930
1.3 Exploded view - rotor assembly............................................................................................................................................................................................................................................................................................................................................................................................................................ 1931
1.4 Removing and installing supercharger...................................................................................................................................................................................................................................................................................................................................................................................................................... 1931
1.5 Checking supercharger for leaks........................................................................................................................................................................................................................................................................................................................................................................................................................... 1936
1.6 Removing and installing magnetic clutch................................................................................................................................................................................................................................................................................................................................................................................................................... 1938
1.7 Removing and installing pulley for supercharger........................................................................................................................................................................................................................................................................................................................................................................................................... 1945
1.8 Removing and installing drive unit........................................................................................................................................................................................................................................................................................................................................................................................................................ 1946
1.9 Removing and installing rotor assembly.................................................................................................................................................................................................................................................................................................................................................................................................................... 1948
1.10 Renewing drive shaft oil seal............................................................................................................................................................................................................................................................................................................................................................................................................................ 1952
1.11 Securing supercharger to engine and gearbox support...................................................................................................................................................................................................................................................................................................................................................................................................... 1954
1.11.1 Securing supercharger to engine and gearbox support for assembly work.............................................................................................................................................................................................................................................................................................................................................................................. 1954
1.11.2 Securing supercharger to engine and gearbox support for leak test.................................................................................................................................................................................................................................................................................................................................................................................. 1956
1.12 Removing and installing sender 1 for turbocharger speed -G688-........................................................................................................................................................................................................................................................................................................................................................................................... 1958
2 Charge air system............................................................................................................................................................................................................................................................................................................................................................................................................................................... 1959
2.1 Exploded view - charge air system......................................................................................................................................................................................................................................................................................................................................................................................................................... 1959
2.2 Exploded view - hose connections for charge air system.................................................................................................................................................................................................................................................................................................................................................................................................... 1960
2.3 Removing and installing charge air cooler................................................................................................................................................................................................................................................................................................................................................................................................................. 1960
2.4 Removing and installing charge pressure sender -G31-/-G447-............................................................................................................................................................................................................................................................................................................................................................................................... 1964
24 – Mixture preparation - injection.................................................................................................................................................................................................................................................................................................................................................................................................................................. 1965
1 Injection system................................................................................................................................................................................................................................................................................................................................................................................................................................................ 1965
1.1 Overview of fitting locations - injection system.......................................................................................................................................................................................................................................................................................................................................................................................................... 1965
1.2 Checking fuel system for leaks............................................................................................................................................................................................................................................................................................................................................................................................................................ 1972
2 Vacuum system................................................................................................................................................................................................................................................................................................................................................................................................................................................... 1973
2.1 Connection diagram - vacuum system........................................................................................................................................................................................................................................................................................................................................................................................................................ 1973
2.2 Checking vacuum system.................................................................................................................................................................................................................................................................................................................................................................................................................................... 1974
3 Air cleaner..................................................................................................................................................................................................................................................................................................................................................................................................................................................... 1976
3.1 Exploded view - air cleaner housing....................................................................................................................................................................................................................................................................................................................................................................................................................... 1976
3.2 Removing and installing air cleaner housing............................................................................................................................................................................................................................................................................................................................................................................................................... 1977
4 Intake manifold................................................................................................................................................................................................................................................................................................................................................................................................................................................. 1979
4.1 Exploded view - intake manifold (bottom section) with fuel rail........................................................................................................................................................................................................................................................................................................................................................................................... 1979
4.2 Removing and installing intake manifold (bottom section) with fuel rail................................................................................................................................................................................................................................................................................................................................................................................... 1981
4.3 Removing and installing throttle valve module -J338-...................................................................................................................................................................................................................................................................................................................................................................................................... 1985
4.4 Removing and installing regulating flap control unit -J808-............................................................................................................................................................................................................................................................................................................................................................................................... 1987
4.5 Removing and installing fuel line......................................................................................................................................................................................................................................................................................................................................................................................................................... 1987
5 Injectors....................................................................................................................................................................................................................................................................................................................................................................................................................................................... 1989
5.1 Exploded view - fuel rail with injectors.................................................................................................................................................................................................................................................................................................................................................................................................................. 1989
5.1.1 Exploded view - fuel rail with injectors, vehicles up to 03.2015.................................................................................................................................................................................................................................................................................................................................................................................... 1989
5.1.2 Exploded view - fuel rail with injectors, vehicles from 04.2015 onwards............................................................................................................................................................................................................................................................................................................................................................................. 1990
5.2 Removing and installing fuel rail......................................................................................................................................................................................................................................................................................................................................................................................................................... 1991
5.3 Removing and installing injectors......................................................................................................................................................................................................................................................................................................................................................................................................................... 1992
5.3.1 Removing and installing injectors, MPI engines...................................................................................................................................................................................................................................................................................................................................................................................................... 1992
5.3.2 Removing and installing injectors, FSI engines...................................................................................................................................................................................................................................................................................................................................................................................................... 1993
5.4 Cleaning injectors........................................................................................................................................................................................................................................................................................................................................................................................................................................ 1997
6 Senders and sensors............................................................................................................................................................................................................................................................................................................................................................................................................................................. 1999
6.1 Removing and installing intake air temperature sender -G42- / intake manifold pressure sender -G71-....................................................................................................................................................................................................................................................................................................................................................... 1999
6.2 Removing and installing fuel pressure sender -G247-....................................................................................................................................................................................................................................................................................................................................................................................................... 1999
6.3 Removing and installing fuel pressure sender for low pressure -G410-...................................................................................................................................................................................................................................................................................................................................................................................... 2000
7 High-pressure pump.............................................................................................................................................................................................................................................................................................................................................................................................................................................. 2002
7.1 Exploded view - high-pressure pump........................................................................................................................................................................................................................................................................................................................................................................................................................ 2002
7.2 Removing and installing high-pressure pump................................................................................................................................................................................................................................................................................................................................................................................................................ 2003
7.3 Removing and installing high-pressure pipe................................................................................................................................................................................................................................................................................................................................................................................................................ 2006
8 Lambda probe.................................................................................................................................................................................................................................................................................................................................................................................................................................................... 2009
8.1 Exploded view - Lambda probe.............................................................................................................................................................................................................................................................................................................................................................................................................................. 2009
8.2 Removing and installing Lambda probe...................................................................................................................................................................................................................................................................................................................................................................................................................... 2010
8.2.1 Removing and installing Lambda probe -G39-/-G130-................................................................................................................................................................................................................................................................................................................................................................................................... 2010
8.2.2 Removing and installing Lambda probe -G108-/-G131-.................................................................................................................................................................................................................................................................................................................................................................................................. 2011
9 Engine control unit............................................................................................................................................................................................................................................................................................................................................................................................................................................. 2014
9.1 Removing and installing engine control unit -J623-........................................................................................................................................................................................................................................................................................................................................................................................................ 2014
9.1.1 Removing and installing engine control unit -J623- without protective housing....................................................................................................................................................................................................................................................................................................................................................................... 2014
9.1.2 Removing and installing engine control unit -J623- with protective housing.......................................................................................................................................................................................................................................................................................................................................................................... 2015
26 – Exhaust system................................................................................................................................................................................................................................................................................................................................................................................................................................................... 2019
1 Exhaust pipes/silencers......................................................................................................................................................................................................................................................................................................................................................................................................................................... 2019
1.1 Exploded view - silencers................................................................................................................................................................................................................................................................................................................................................................................................................................. 2019
1.2 Separating exhaust pipes/silencers........................................................................................................................................................................................................................................................................................................................................................................................................................ 2021
1.3 Removing and installing front silencers................................................................................................................................................................................................................................................................................................................................................................................................................... 2022
1.4 Removing and installing silencers......................................................................................................................................................................................................................................................................................................................................................................................................................... 2024
1.5 Stress-free alignment of exhaust system................................................................................................................................................................................................................................................................................................................................................................................................................... 2024
1.6 Checking exhaust system for leaks......................................................................................................................................................................................................................................................................................................................................................................................................................... 2025
2 Emission control system......................................................................................................................................................................................................................................................................................................................................................................................................................................... 2027
2.1 Exploded view - emission control system................................................................................................................................................................................................................................................................................................................................................................................................................... 2027
2.2 Removing and installing catalytic converter............................................................................................................................................................................................................................................................................................................................................................................................................... 2028
2.2.1 Removing and installing catalytic converter (left-side)............................................................................................................................................................................................................................................................................................................................................................................................. 2028
2.2.2 Removing and installing catalytic converter (right-side)............................................................................................................................................................................................................................................................................................................................................................................................ 2029
3 Secondary air system............................................................................................................................................................................................................................................................................................................................................................................................................................................ 2030
3.1 Exploded view - secondary air system...................................................................................................................................................................................................................................................................................................................................................................................................................... 2030
3.2 Removing and installing secondary air pump motor -V101-................................................................................................................................................................................................................................................................................................................................................................................................... 2032
3.3 Checking combination valve................................................................................................................................................................................................................................................................................................................................................................................................................................ 2032
3.4 Removing and installing combination valve................................................................................................................................................................................................................................................................................................................................................................................................................. 2034
3.4.1 Removing and installing combination valve (left-side)............................................................................................................................................................................................................................................................................................................................................................................................... 2034
3.4.2 Removing and installing combination valve (right-side).............................................................................................................................................................................................................................................................................................................................................................................................. 2036
4 Exhaust manifolds............................................................................................................................................................................................................................................................................................................................................................................................................................................... 2038
4.1 Exploded view - exhaust manifold.......................................................................................................................................................................................................................................................................................................................................................................................................................... 2038
4.2 Removing and installing exhaust manifolds................................................................................................................................................................................................................................................................................................................................................................................................................. 2039
4.2.1 Removing and installing exhaust manifold (left-side)................................................................................................................................................................................................................................................................................................................................................................................................ 2039
4.2.2 Removing and installing exhaust manifold (right-side)............................................................................................................................................................................................................................................................................................................................................................................................... 2041
28 – Ignition system.................................................................................................................................................................................................................................................................................................................................................................................................................................................. 2044
1 Ignition system................................................................................................................................................................................................................................................................................................................................................................................................................................................. 2044
1.1 Exploded view - ignition system........................................................................................................................................................................................................................................................................................................................................................................................................................... 2044
1.2 Test data, spark plugs.................................................................................................................................................................................................................................................................................................................................................................................................................................... 2045
1.3 Removing and installing ignition coils with output stages................................................................................................................................................................................................................................................................................................................................................................................................. 2045
1.4 Removing and installing knock sensor...................................................................................................................................................................................................................................................................................................................................................................................................................... 2047
1.5 Removing and installing Hall senders...................................................................................................................................................................................................................................................................................................................................................................................................................... 2048
1.6 Removing and installing engine speed sender -G28-......................................................................................................................................................................................................................................................................................................................................................................................................... 2048
6-cylinder_direct_injection_engine_with_supercharger_(3_0_ltr__4-valve_TFSI).............................................................................................................................................................................................................................................................................................................................................................................................. 2049
00 – Technical data................................................................................................................................................................................................................................................................................................................................................................................................................................................... 2057
1 Identification.................................................................................................................................................................................................................................................................................................................................................................................................................................................. 2057
1.1 Engine identification number/engine data.................................................................................................................................................................................................................................................................................................................................................................................................................. 2057
2 General notes................................................................................................................................................................................................................................................................................................................................................................................................................................................... 2059
2.1 General notes on self-diagnosis........................................................................................................................................................................................................................................................................................................................................................................................................................... 2059
2.2 General notes on ignition system.......................................................................................................................................................................................................................................................................................................................................................................................................................... 2059
3 Safety precautions.............................................................................................................................................................................................................................................................................................................................................................................................................................................. 2060
3.1 Safety precautions when working on the fuel system........................................................................................................................................................................................................................................................................................................................................................................................................ 2060
3.2 Safety precautions when working on the cooling system..................................................................................................................................................................................................................................................................................................................................................................................................... 2061
3.3 Safety precautions when working on vehicles with start/stop system........................................................................................................................................................................................................................................................................................................................................................................................ 2062
3.4 Safety precautions when using testers and measuring instruments during a road test........................................................................................................................................................................................................................................................................................................................................................................ 2062
3.5 Safety precautions when working on the exhaust system..................................................................................................................................................................................................................................................................................................................................................................................................... 2063
3.6 Safety precautions when working on the subframe........................................................................................................................................................................................................................................................................................................................................................................................................... 2063
3.7 Safety precautions when working on the ignition system.................................................................................................................................................................................................................................................................................................................................................................................................... 2063
4 Repair instructions............................................................................................................................................................................................................................................................................................................................................................................................................................................. 2065
4.1 Rules for cleanliness..................................................................................................................................................................................................................................................................................................................................................................................................................................... 2065
4.2 Foreign particles in engine............................................................................................................................................................................................................................................................................................................................................................................................................................... 2065
4.3 Contact corrosion......................................................................................................................................................................................................................................................................................................................................................................................................................................... 2065
4.4 Routing and attachment of pipes, hoses and wiring......................................................................................................................................................................................................................................................................................................................................................................................................... 2066
4.5 Installing radiators and condensers....................................................................................................................................................................................................................................................................................................................................................................................................................... 2066
4.6 Checking vacuum system.................................................................................................................................................................................................................................................................................................................................................................................................................................... 2066
5 Technical data.................................................................................................................................................................................................................................................................................................................................................................................................................................................. 2067
5.1 Technical data of injection system........................................................................................................................................................................................................................................................................................................................................................................................................................ 2067
10 – Removing and installing engine................................................................................................................................................................................................................................................................................................................................................................................................................................... 2068
1 Removing and installing engine.................................................................................................................................................................................................................................................................................................................................................................................................................................. 2068
1.1 Removing engine........................................................................................................................................................................................................................................................................................................................................................................................................................................... 2068
1.1.1 Removing engine - vehicles with manual gearbox...................................................................................................................................................................................................................................................................................................................................................................................................... 2068
1.1.2 Removing engine - vehicles with dual clutch gearbox 0B5............................................................................................................................................................................................................................................................................................................................................................................................. 2090
1.2 Separating engine and gearbox............................................................................................................................................................................................................................................................................................................................................................................................................................. 2112
1.2.1 Separating engine and gearbox - vehicles with manual gearbox........................................................................................................................................................................................................................................................................................................................................................................................ 2112
1.2.2 Separating engine and gearbox - vehicles with dual clutch gearbox 0B5............................................................................................................................................................................................................................................................................................................................................................................... 2116
1.3 Securing engine to engine and gearbox support............................................................................................................................................................................................................................................................................................................................................................................................................. 2123
1.4 Installing engine......................................................................................................................................................................................................................................................................................................................................................................................................................................... 2127
1.4.1 Installing engine, vehicles with manual gearbox..................................................................................................................................................................................................................................................................................................................................................................................................... 2127
1.4.2 Installing engine, vehicles with dual clutch gearbox 0B5............................................................................................................................................................................................................................................................................................................................................................................................ 2134
2 Assembly mountings.............................................................................................................................................................................................................................................................................................................................................................................................................................................. 2143
2.1 Exploded view - assembly mountings........................................................................................................................................................................................................................................................................................................................................................................................................................ 2143
2.2 Removing and installing engine mounting (left-side)....................................................................................................................................................................................................................................................................................................................................................................................................... 2144
2.3 Removing and installing engine mounting (right-side)...................................................................................................................................................................................................................................................................................................................................................................................................... 2147
13 – Crankshaft group................................................................................................................................................................................................................................................................................................................................................................................................................................................. 2150
1 Cylinder block (pulley end)..................................................................................................................................................................................................................................................................................................................................................................................................................................... 2150
1.1 Exploded view - poly V-belt drive......................................................................................................................................................................................................................................................................................................................................................................................................................... 2150
1.1.1 Exploded view - poly V-belt drive for supercharger.................................................................................................................................................................................................................................................................................................................................................................................................. 2150
1.1.2 Exploded view - poly V-belt drive for vehicles with hydraulic power steering........................................................................................................................................................................................................................................................................................................................................................................ 2152
1.1.3 Exploded view - poly V-belt drive for vehicles with electromechanical power steering................................................................................................................................................................................................................................................................................................................................................................ 2154
1.2 Removing and installing poly V-belt....................................................................................................................................................................................................................................................................................................................................................................................................................... 2155
1.2.1 Removing and installing poly V-belt for supercharger................................................................................................................................................................................................................................................................................................................................................................................................ 2155
1.2.2 Removing and installing poly V-belt - vehicles with hydraulic power steering........................................................................................................................................................................................................................................................................................................................................................................ 2157
1.2.3 Removing and installing poly V-belt - vehicles with electromechanical power steering................................................................................................................................................................................................................................................................................................................................................................ 2159
1.3 Removing and installing tensioner for poly V-belt......................................................................................................................................................................................................................................................................................................................................................................................................... 2162
1.3.1 Removing and installing poly V-belt tensioner for supercharger...................................................................................................................................................................................................................................................................................................................................................................................... 2162
1.3.2 Removing and installing tensioner for poly V-belt - vehicles with electromechanical power steering.................................................................................................................................................................................................................................................................................................................................................. 2163
1.3.3 Removing and installing tensioner for poly V-belt - vehicles with hydraulic power steering.......................................................................................................................................................................................................................................................................................................................................................... 2165
1.4 Removing and installing vibration damper.................................................................................................................................................................................................................................................................................................................................................................................................................. 2166
1.5 Removing and installing sealing flange (pulley end)....................................................................................................................................................................................................................................................................................................................................................................................................... 2170
2 Cylinder block (gearbox end).................................................................................................................................................................................................................................................................................................................................................................................................................................... 2173
2.1 Exploded view - drive plate............................................................................................................................................................................................................................................................................................................................................................................................................................... 2173
2.2 Removing and installing drive plate....................................................................................................................................................................................................................................................................................................................................................................................................................... 2173
2.3 Removing and installing sender wheel...................................................................................................................................................................................................................................................................................................................................................................................................................... 2174
2.4 Checking sender wheel..................................................................................................................................................................................................................................................................................................................................................................................................................................... 2175
2.5 Renewing crankshaft oil seal (gearbox end)................................................................................................................................................................................................................................................................................................................................................................................................................ 2176
2.6 Renewing needle bearing in drive plate.................................................................................................................................................................................................................................................................................................................................................................................................................... 2178
3 Crankshaft...................................................................................................................................................................................................................................................................................................................................................................................................................................................... 2180
3.1 Exploded view - crankshaft................................................................................................................................................................................................................................................................................................................................................................................................................................ 2180
3.2 Crankshaft dimensions..................................................................................................................................................................................................................................................................................................................................................................................................................................... 2183
3.3 Measuring axial clearance of crankshaft................................................................................................................................................................................................................................................................................................................................................................................................................... 2183
3.4 Measuring radial clearance of crankshaft.................................................................................................................................................................................................................................................................................................................................................................................................................. 2184
4 Balance shaft................................................................................................................................................................................................................................................................................................................................................................................................................................................... 2186
4.1 Exploded view - balance shaft............................................................................................................................................................................................................................................................................................................................................................................................................................. 2186
4.2 Removing and installing balance shaft..................................................................................................................................................................................................................................................................................................................................................................................................................... 2186
5 Pistons and conrods............................................................................................................................................................................................................................................................................................................................................................................................................................................. 2189
5.1 Exploded view - pistons and conrods....................................................................................................................................................................................................................................................................................................................................................................................................................... 2189
5.2 Removing and installing pistons........................................................................................................................................................................................................................................................................................................................................................................................................................... 2191
5.3 Checking pistons and cylinder bores....................................................................................................................................................................................................................................................................................................................................................................................................................... 2192
5.4 Checking radial clearance of conrod bearings.............................................................................................................................................................................................................................................................................................................................................................................................................. 2193
15 – Cylinder head, valve gear........................................................................................................................................................................................................................................................................................................................................................................................................................................ 2195
1 Cylinder head................................................................................................................................................................................................................................................................................................................................................................................................................................................... 2195
1.1 Exploded view - cylinder head............................................................................................................................................................................................................................................................................................................................................................................................................................. 2195
1.2 Removing and installing cylinder head..................................................................................................................................................................................................................................................................................................................................................................................................................... 2198
1.3 Removing and installing cylinder head cover (left-side)................................................................................................................................................................................................................................................................................................................................................................................................... 2205
1.4 Removing and installing cylinder head cover (right-side).................................................................................................................................................................................................................................................................................................................................................................................................. 2206
1.5 Checking compression...................................................................................................................................................................................................................................................................................................................................................................................................................................... 2206
2 Timing chain cover.............................................................................................................................................................................................................................................................................................................................................................................................................................................. 2209
2.1 Exploded view - timing chain cover........................................................................................................................................................................................................................................................................................................................................................................................................................ 2209
2.2 Removing and installing timing chain covers (left and right).............................................................................................................................................................................................................................................................................................................................................................................................. 2211
2.3 Removing and installing timing chain cover (bottom)....................................................................................................................................................................................................................................................................................................................................................................................................... 2215
3 Chain drive..................................................................................................................................................................................................................................................................................................................................................................................................................................................... 2222
3.1 Exploded view - camshaft timing chains.................................................................................................................................................................................................................................................................................................................................................................................................................... 2222
3.2 Exploded view - drive chain for valve gear................................................................................................................................................................................................................................................................................................................................................................................................................ 2225
3.3 Exploded view - drive chain for balance shaft and oil pump................................................................................................................................................................................................................................................................................................................................................................................................ 2226
3.4 Removing and installing camshaft timing chain............................................................................................................................................................................................................................................................................................................................................................................................................. 2227
3.5 Removing camshaft timing chain from camshafts............................................................................................................................................................................................................................................................................................................................................................................................................. 2229
3.6 Removing and installing drive chain for valve gear........................................................................................................................................................................................................................................................................................................................................................................................................ 2240
3.7 Removing and installing drive chain for auxiliary drive................................................................................................................................................................................................................................................................................................................................................................................................... 2242
4 Valve gear...................................................................................................................................................................................................................................................................................................................................................................................................................................................... 2246
4.1 Exploded view - valve gear................................................................................................................................................................................................................................................................................................................................................................................................................................ 2246
4.2 Measuring axial clearance of camshaft..................................................................................................................................................................................................................................................................................................................................................................................................................... 2249
4.3 Measuring radial clearance of camshaft.................................................................................................................................................................................................................................................................................................................................................................................................................... 2250
4.4 Removing and installing camshaft.......................................................................................................................................................................................................................................................................................................................................................................................................................... 2250
4.5 Checking hydraulic valve compensation elements............................................................................................................................................................................................................................................................................................................................................................................................................ 2256
4.6 Removing and installing valve stem oil seals.............................................................................................................................................................................................................................................................................................................................................................................................................. 2258
4.6.1 Renewing valve stem oil seals with cylinder head removed............................................................................................................................................................................................................................................................................................................................................................................................ 2258
4.6.2 Renewing valve stem oil seals with cylinder head installed.......................................................................................................................................................................................................................................................................................................................................................................................... 2261
5 Inlet and exhaust valves........................................................................................................................................................................................................................................................................................................................................................................................................................................ 2266
5.1 Checking valve guides..................................................................................................................................................................................................................................................................................................................................................................................................................................... 2266
5.2 Checking valves........................................................................................................................................................................................................................................................................................................................................................................................................................................... 2267
5.3 Valve dimensions.......................................................................................................................................................................................................................................................................................................................................................................................................................................... 2268
17 – Lubrication...................................................................................................................................................................................................................................................................................................................................................................................................................................................... 2269
1 Sump/oil pump................................................................................................................................................................................................................................................................................................................................................................................................................................................... 2269
1.1 Exploded view - sump/oil pump............................................................................................................................................................................................................................................................................................................................................................................................................................. 2269
1.2 Engine oil................................................................................................................................................................................................................................................................................................................................................................................................................................................ 2272
1.3 Removing and installing sump (bottom section)............................................................................................................................................................................................................................................................................................................................................................................................................. 2272
1.4 Removing and installing sump (top section)................................................................................................................................................................................................................................................................................................................................................................................................................ 2275
1.5 Removing and installing oil pump.......................................................................................................................................................................................................................................................................................................................................................................................................................... 2278
1.6 Removing and installing oil level and oil temperature sender -G266-....................................................................................................................................................................................................................................................................................................................................................................................... 2279
1.7 Checking oil level........................................................................................................................................................................................................................................................................................................................................................................................................................................ 2279
2 Engine oil cooler............................................................................................................................................................................................................................................................................................................................................................................................................................................... 2280
2.1 Removing and installing engine oil cooler................................................................................................................................................................................................................................................................................................................................................................................................................. 2280
3 Crankcase breather.............................................................................................................................................................................................................................................................................................................................................................................................................................................. 2282
3.1 Exploded view - crankcase breather system................................................................................................................................................................................................................................................................................................................................................................................................................. 2282
3.2 Removing and installing crankcase breather hoses.......................................................................................................................................................................................................................................................................................................................................................................................................... 2284
3.2.1 Removing and installing crankcase breather hoses, rest-of-world vehicles............................................................................................................................................................................................................................................................................................................................................................................ 2284
3.2.2 Renewing crankcase breather hoses, USA vehicles..................................................................................................................................................................................................................................................................................................................................................................................................... 2284
3.3 Removing and installing oil separator..................................................................................................................................................................................................................................................................................................................................................................................................................... 2285
4 Oil filter/oil pressure switches................................................................................................................................................................................................................................................................................................................................................................................................................................ 2287
4.1 Exploded view - oil filter/oil pressure switch............................................................................................................................................................................................................................................................................................................................................................................................................ 2287
4.2 Removing and installing oil pressure switch -F22-......................................................................................................................................................................................................................................................................................................................................................................................................... 2288
4.3 Removing and installing oil pressure switch for reduced oil pressure -F378-............................................................................................................................................................................................................................................................................................................................................................................... 2290
4.4 Checking oil pressure..................................................................................................................................................................................................................................................................................................................................................................................................................................... 2291
4.5 Checking oil pressure and oil pressure switch............................................................................................................................................................................................................................................................................................................................................................................................................. 2292
4.6 Removing and installing oil filter housing................................................................................................................................................................................................................................................................................................................................................................................................................ 2292
4.7 Removing and installing valve for oil pressure control -N428-............................................................................................................................................................................................................................................................................................................................................................................................. 2294
19 – Cooling.......................................................................................................................................................................................................................................................................................................................................................................................................................................................... 2297
1 Cooling system/coolant.......................................................................................................................................................................................................................................................................................................................................................................................................................................... 2297
1.1 Connection diagram - coolant hoses........................................................................................................................................................................................................................................................................................................................................................................................................................ 2297
1.2 Draining and filling cooling system....................................................................................................................................................................................................................................................................................................................................................................................................................... 2304
1.3 Checking cooling system for leaks......................................................................................................................................................................................................................................................................................................................................................................................................................... 2312
2 Coolant pump/thermostat assembly................................................................................................................................................................................................................................................................................................................................................................................................................................ 2315
2.1 Exploded view - coolant pump and thermostat............................................................................................................................................................................................................................................................................................................................................................................................................... 2315
2.2 Exploded view - electric coolant pump..................................................................................................................................................................................................................................................................................................................................................................................................................... 2317
2.2.1 Exploded view - continued coolant circulation pump -V51-............................................................................................................................................................................................................................................................................................................................................................................................ 2317
2.3 Removing and installing electric coolant pump............................................................................................................................................................................................................................................................................................................................................................................................................. 2317
2.3.1 Removing and installing charge air cooling pump -V188-.............................................................................................................................................................................................................................................................................................................................................................................................. 2317
2.3.2 Removing and installing continued coolant circulation pump -V51-.................................................................................................................................................................................................................................................................................................................................................................................... 2319
2.4 Removing and installing coolant pump...................................................................................................................................................................................................................................................................................................................................................................................................................... 2320
2.5 Removing and installing thermostat........................................................................................................................................................................................................................................................................................................................................................................................................................ 2322
2.6 Checking thermostat....................................................................................................................................................................................................................................................................................................................................................................................................................................... 2323
2.7 Removing and installing coolant temperature sender -G62-.................................................................................................................................................................................................................................................................................................................................................................................................. 2324
2.8 Removing and installing temperature sender for engine temperature regulation -G694-....................................................................................................................................................................................................................................................................................................................................................................... 2325
3 Coolant pipes................................................................................................................................................................................................................................................................................................................................................................................................................................................... 2326
3.1 Exploded view - coolant pipes............................................................................................................................................................................................................................................................................................................................................................................................................................. 2326
3.2 Fitting coolant hoses..................................................................................................................................................................................................................................................................................................................................................................................................................................... 2330
3.3 Removing and installing coolant pipes (left-side)......................................................................................................................................................................................................................................................................................................................................................................................................... 2330
3.4 Removing and installing coolant pipes (front left)........................................................................................................................................................................................................................................................................................................................................................................................................ 2331
3.5 Removing and installing coolant pipes (front)............................................................................................................................................................................................................................................................................................................................................................................................................. 2334
3.6 Removing and installing coolant pipes (top)............................................................................................................................................................................................................................................................................................................................................................................................................... 2337
3.7 Removing and installing coolant pipes on supercharger..................................................................................................................................................................................................................................................................................................................................................................................................... 2339
4 Radiator/radiator fans.......................................................................................................................................................................................................................................................................................................................................................................................................................................... 2343
4.1 Exploded view - radiator/radiator fans.................................................................................................................................................................................................................................................................................................................................................................................................................... 2343
4.2 Removing and installing radiator.......................................................................................................................................................................................................................................................................................................................................................................................................................... 2347
4.3 Removing and installing radiator cowl..................................................................................................................................................................................................................................................................................................................................................................................................................... 2353
4.4 Removing and installing water radiator for charge air cooling circuit (front)............................................................................................................................................................................................................................................................................................................................................................................. 2358
4.5 Removing and installing water radiator for charge air cooling circuit (left-side)......................................................................................................................................................................................................................................................................................................................................................................... 2362
4.6 Removing and installing radiator fans..................................................................................................................................................................................................................................................................................................................................................................................................................... 2364
4.6.1 Removing and installing radiator fans -V7-/-V177- - version 1....................................................................................................................................................................................................................................................................................................................................................................................... 2364
4.6.2 Removing and installing radiator fans -V7-/-V177- - version 2....................................................................................................................................................................................................................................................................................................................................................................................... 2364
21 – Turbocharging/supercharging...................................................................................................................................................................................................................................................................................................................................................................................................................................... 2366
1 Charge air system............................................................................................................................................................................................................................................................................................................................................................................................................................................... 2366
1.1 Exploded view - charge air system......................................................................................................................................................................................................................................................................................................................................................................................................................... 2366
1.2 Removing and installing charge air cooler................................................................................................................................................................................................................................................................................................................................................................................................................. 2367
1.3 Removing and installing charge pressure sender............................................................................................................................................................................................................................................................................................................................................................................................................ 2371
2 Supercharger.................................................................................................................................................................................................................................................................................................................................................................................................................................................... 2372
2.1 Exploded view - supercharger.............................................................................................................................................................................................................................................................................................................................................................................................................................. 2372
2.2 Exploded view - drive unit................................................................................................................................................................................................................................................................................................................................................................................................................................ 2375
2.3 Removing and installing supercharger...................................................................................................................................................................................................................................................................................................................................................................................................................... 2375
2.4 Checking supercharger for leaks........................................................................................................................................................................................................................................................................................................................................................................................................................... 2379
2.5 Removing and installing drive unit and damper spring...................................................................................................................................................................................................................................................................................................................................................................................................... 2381
2.6 Securing supercharger to engine and gearbox support for leak test......................................................................................................................................................................................................................................................................................................................................................................................... 2383
2.7 Securing supercharger to engine and gearbox support....................................................................................................................................................................................................................................................................................................................................................................................................... 2385
24 – Mixture preparation - injection.................................................................................................................................................................................................................................................................................................................................................................................................................................. 2387
1 Injection system................................................................................................................................................................................................................................................................................................................................................................................................................................................ 2387
1.1 Overview of fitting locations - injection system.......................................................................................................................................................................................................................................................................................................................................................................................................... 2387
1.2 Checking fuel system for leaks............................................................................................................................................................................................................................................................................................................................................................................................................................ 2397
1.3 Reducing pressure in high-pressure section of injection system............................................................................................................................................................................................................................................................................................................................................................................................ 2398
2 Vacuum system................................................................................................................................................................................................................................................................................................................................................................................................................................................... 2400
2.1 Connection diagram - vacuum system........................................................................................................................................................................................................................................................................................................................................................................................................................ 2400
2.2 Checking vacuum system.................................................................................................................................................................................................................................................................................................................................................................................................................................... 2401
2.3 Removing and installing vacuum unit for actuating intake manifold flaps................................................................................................................................................................................................................................................................................................................................................................................... 2402
2.3.1 Removing and installing vacuum unit for actuating intake manifold flaps, cylinder bank 1 (right-side)............................................................................................................................................................................................................................................................................................................................................... 2402
2.3.2 Removing and installing vacuum unit for actuating intake manifold flaps, cylinder bank 2 (left-side)................................................................................................................................................................................................................................................................................................................................................ 2404
3 Air cleaner..................................................................................................................................................................................................................................................................................................................................................................................................................................................... 2408
3.1 Exploded view - air cleaner housing....................................................................................................................................................................................................................................................................................................................................................................................................................... 2408
3.2 Removing and installing air filter element................................................................................................................................................................................................................................................................................................................................................................................................................ 2409
4 Intake manifold................................................................................................................................................................................................................................................................................................................................................................................................................................................. 2411
4.1 Exploded view - intake manifold (bottom section) with fuel rail........................................................................................................................................................................................................................................................................................................................................................................................... 2411
4.2 Removing and installing intake manifold (bottom section) with fuel rail................................................................................................................................................................................................................................................................................................................................................................................... 2413
4.3 Removing and installing throttle valve module -J338-...................................................................................................................................................................................................................................................................................................................................................................................................... 2417
4.4 Removing and installing regulating flap control unit -J808-............................................................................................................................................................................................................................................................................................................................................................................................... 2418
4.5 Cleaning throttle valve module............................................................................................................................................................................................................................................................................................................................................................................................................................ 2419
5 Injectors....................................................................................................................................................................................................................................................................................................................................................................................................................................................... 2421
5.1 Removing and installing injectors......................................................................................................................................................................................................................................................................................................................................................................................................................... 2421
5.2 Cleaning injectors........................................................................................................................................................................................................................................................................................................................................................................................................................................ 2425
6 Senders and sensors............................................................................................................................................................................................................................................................................................................................................................................................................................................. 2427
6.1 Removing and installing control unit for structure-borne sound -J869- and actuator for structure-borne sound -R214-....................................................................................................................................................................................................................................................................................................................................... 2427
7 Engine control unit............................................................................................................................................................................................................................................................................................................................................................................................................................................. 2428
7.1 Wiring and component check with test box -V.A.G 1598/42-.................................................................................................................................................................................................................................................................................................................................................................................................. 2428
7.2 Removing and installing engine control unit -J623-........................................................................................................................................................................................................................................................................................................................................................................................................ 2430
8 High-pressure pump.............................................................................................................................................................................................................................................................................................................................................................................................................................................. 2434
8.1 Exploded view - high-pressure pump........................................................................................................................................................................................................................................................................................................................................................................................................................ 2434
8.2 Removing and installing high-pressure pump................................................................................................................................................................................................................................................................................................................................................................................................................ 2435
8.3 Removing and installing high-pressure pipe................................................................................................................................................................................................................................................................................................................................................................................................................ 2438
8.4 Checking fuel pressure and residual pressure (up to high-pressure pump)................................................................................................................................................................................................................................................................................................................................................................................... 2440
9 Lambda probe.................................................................................................................................................................................................................................................................................................................................................................................................................................................... 2445
9.1 Exploded view - Lambda probe.............................................................................................................................................................................................................................................................................................................................................................................................................................. 2445
9.2 Removing and installing Lambda probe...................................................................................................................................................................................................................................................................................................................................................................................................................... 2446
9.2.1 Removing and installing Lambda probe -G39-.......................................................................................................................................................................................................................................................................................................................................................................................................... 2446
9.2.2 Removing and installing Lambda probe after catalytic converter -G130-............................................................................................................................................................................................................................................................................................................................................................................... 2448
9.2.3 Removing and installing Lambda probe 2 -G108-....................................................................................................................................................................................................................................................................................................................................................................................................... 2450
9.2.4 Removing and installing Lambda probe 2 after catalytic converter -G131-............................................................................................................................................................................................................................................................................................................................................................................. 2452
26 – Exhaust system................................................................................................................................................................................................................................................................................................................................................................................................................................................... 2455
1 Exhaust pipes/silencers......................................................................................................................................................................................................................................................................................................................................................................................................................................... 2455
1.1 Exploded view - silencers................................................................................................................................................................................................................................................................................................................................................................................................................................. 2455
1.2 Removing and installing front silencer.................................................................................................................................................................................................................................................................................................................................................................................................................... 2458
1.3 Separating exhaust pipes/silencers........................................................................................................................................................................................................................................................................................................................................................................................................................ 2459
1.4 Renewing tailpipes........................................................................................................................................................................................................................................................................................................................................................................................................................................ 2461
1.5 Stress-free alignment of exhaust system................................................................................................................................................................................................................................................................................................................................................................................................................... 2461
1.6 Aligning tailpipes........................................................................................................................................................................................................................................................................................................................................................................................................................................ 2462
1.7 Checking exhaust system for leaks......................................................................................................................................................................................................................................................................................................................................................................................................................... 2463
2 Emission control system......................................................................................................................................................................................................................................................................................................................................................................................................................................... 2464
2.1 Removing and installing catalytic converter (left-side)................................................................................................................................................................................................................................................................................................................................................................................................... 2464
2.2 Removing and installing catalytic converter (right-side).................................................................................................................................................................................................................................................................................................................................................................................................. 2465
3 Secondary air system............................................................................................................................................................................................................................................................................................................................................................................................................................................ 2466
3.1 Exploded view - secondary air system...................................................................................................................................................................................................................................................................................................................................................................................................................... 2466
3.2 Removing and installing secondary air pump motor -V101-................................................................................................................................................................................................................................................................................................................................................................................................... 2468
3.3 Checking combination valve for correct operation and leaks................................................................................................................................................................................................................................................................................................................................................................................................ 2469
3.4 Removing and installing combination valve (left-side)..................................................................................................................................................................................................................................................................................................................................................................................................... 2471
3.5 Removing and installing combination valve (right-side).................................................................................................................................................................................................................................................................................................................................................................................................... 2473
3.6 Removing and installing sender 1 for secondary air pressure -G609-........................................................................................................................................................................................................................................................................................................................................................................................ 2475
4 Exhaust manifold................................................................................................................................................................................................................................................................................................................................................................................................................................................ 2476
4.1 Exploded view - exhaust manifold.......................................................................................................................................................................................................................................................................................................................................................................................................................... 2476
4.2 Removing and installing exhaust manifold (left-side)...................................................................................................................................................................................................................................................................................................................................................................................................... 2477
4.3 Removing and installing exhaust manifold (right-side)..................................................................................................................................................................................................................................................................................................................................................................................................... 2479
28 – Ignition system.................................................................................................................................................................................................................................................................................................................................................................................................................................................. 2482
1 Ignition system................................................................................................................................................................................................................................................................................................................................................................................................................................................. 2482
1.1 Exploded view - ignition system........................................................................................................................................................................................................................................................................................................................................................................................................................... 2482
1.2 Test data, spark plugs.................................................................................................................................................................................................................................................................................................................................................................................................................................... 2483
1.3 Removing and installing ignition coils.................................................................................................................................................................................................................................................................................................................................................................................................................... 2483
1.4 Removing and installing knock sensor...................................................................................................................................................................................................................................................................................................................................................................................................................... 2485
1.5 Removing and installing Hall senders...................................................................................................................................................................................................................................................................................................................................................................................................................... 2486
1.6 Removing and installing engine speed sender -G28-......................................................................................................................................................................................................................................................................................................................................................................................................... 2487
6-cylinder_direct_petrol_injection_engine_(3_2_ltr__4-valve).............................................................................................................................................................................................................................................................................................................................................................................................................. 2488
00 – Technical data................................................................................................................................................................................................................................................................................................................................................................................................................................................... 2494
1 Identification.................................................................................................................................................................................................................................................................................................................................................................................................................................................. 2494
1.1 Engine identification number/engine data.................................................................................................................................................................................................................................................................................................................................................................................................................. 2495
2 Safety precautions.............................................................................................................................................................................................................................................................................................................................................................................................................................................. 2497
2.1 Safety precautions when working on the fuel system........................................................................................................................................................................................................................................................................................................................................................................................................ 2497
2.2 Safety precautions when using testers and measuring instruments during a road test........................................................................................................................................................................................................................................................................................................................................................................ 2498
2.3 Safety precautions when working on the subframe........................................................................................................................................................................................................................................................................................................................................................................................................... 2499
2.4 Safety precautions when working on the cooling system..................................................................................................................................................................................................................................................................................................................................................................................................... 2499
2.5 Safety precautions when working on the ignition system.................................................................................................................................................................................................................................................................................................................................................................................................... 2499
3 Repair instructions............................................................................................................................................................................................................................................................................................................................................................................................................................................. 2501
3.1 Rules for cleanliness..................................................................................................................................................................................................................................................................................................................................................................................................................................... 2501
3.2 Foreign particles in engine............................................................................................................................................................................................................................................................................................................................................................................................................................... 2501
3.3 Contact corrosion......................................................................................................................................................................................................................................................................................................................................................................................................................................... 2501
3.4 Routing and attachment of pipes, hoses and wiring......................................................................................................................................................................................................................................................................................................................................................................................................... 2502
3.5 Installing radiators and condensers....................................................................................................................................................................................................................................................................................................................................................................................................................... 2502
3.6 Checking vacuum system.................................................................................................................................................................................................................................................................................................................................................................................................................................... 2502
3.7 General notes on self-diagnosis........................................................................................................................................................................................................................................................................................................................................................................................................................... 2503
3.8 General notes on ignition system.......................................................................................................................................................................................................................................................................................................................................................................................................................... 2503
4 Technical data.................................................................................................................................................................................................................................................................................................................................................................................................................................................. 2504
4.1 Technical data of injection system........................................................................................................................................................................................................................................................................................................................................................................................................................ 2504
10 – Removing and installing engine................................................................................................................................................................................................................................................................................................................................................................................................................................... 2505
1 Removing and installing engine.................................................................................................................................................................................................................................................................................................................................................................................................................................. 2505
1.1 Removing engine........................................................................................................................................................................................................................................................................................................................................................................................................................................... 2505
1.1.1 Removing engine, vehicles with manual gearbox....................................................................................................................................................................................................................................................................................................................................................................................................... 2505
1.1.2 Removing engine - vehicles with multitronic gearbox 0AW............................................................................................................................................................................................................................................................................................................................................................................................. 2524
1.1.3 Removing engine - vehicles with automatic gearbox 0B6............................................................................................................................................................................................................................................................................................................................................................................................... 2543
1.2 Separating engine and gearbox............................................................................................................................................................................................................................................................................................................................................................................................................................. 2562
1.2.1 Separating engine and gearbox - vehicles with manual gearbox........................................................................................................................................................................................................................................................................................................................................................................................ 2562
1.2.2 Separating engine and gearbox - vehicles with multitronic gearbox 0AW............................................................................................................................................................................................................................................................................................................................................................................... 2567
1.2.3 Separating engine and gearbox - vehicles with automatic gearbox 0B6................................................................................................................................................................................................................................................................................................................................................................................. 2571
1.3 Securing engine to engine and gearbox support............................................................................................................................................................................................................................................................................................................................................................................................................. 2576
1.4 Installing engine......................................................................................................................................................................................................................................................................................................................................................................................................................................... 2580
1.4.1 Installing engine, vehicles with manual gearbox..................................................................................................................................................................................................................................................................................................................................................................................................... 2580
1.4.2 Installing engine - vehicles with multitronic gearbox 0AW........................................................................................................................................................................................................................................................................................................................................................................................... 2588
1.4.3 Installing engine - vehicles with automatic gearbox 0B6............................................................................................................................................................................................................................................................................................................................................................................................. 2595
2 Assembly mountings.............................................................................................................................................................................................................................................................................................................................................................................................................................................. 2603
2.1 Exploded view - assembly mountings........................................................................................................................................................................................................................................................................................................................................................................................................................ 2603
2.2 Removing and installing engine mounting (left-side)....................................................................................................................................................................................................................................................................................................................................................................................................... 2603
2.3 Removing and installing engine mounting (right-side)...................................................................................................................................................................................................................................................................................................................................................................................................... 2606
13 – Crankshaft group................................................................................................................................................................................................................................................................................................................................................................................................................................................. 2610
1 Cylinder block (pulley end)..................................................................................................................................................................................................................................................................................................................................................................................................................................... 2610
1.1 Exploded view - poly V-belt drive......................................................................................................................................................................................................................................................................................................................................................................................................................... 2610
1.2 Removing and installing poly V-belt....................................................................................................................................................................................................................................................................................................................................................................................................................... 2612
1.3 Removing and installing tensioner for poly V-belt......................................................................................................................................................................................................................................................................................................................................................................................................... 2613
1.4 Removing and installing vibration damper.................................................................................................................................................................................................................................................................................................................................................................................................................. 2614
1.5 Removing and installing sealing flange (pulley end)....................................................................................................................................................................................................................................................................................................................................................................................................... 2614
2 Cylinder block (gearbox end).................................................................................................................................................................................................................................................................................................................................................................................................................................... 2618
2.1 Exploded view - drive plate............................................................................................................................................................................................................................................................................................................................................................................................................................... 2618
2.2 Removing and installing drive plate....................................................................................................................................................................................................................................................................................................................................................................................................................... 2618
2.3 Renewing needle bearing in drive plate.................................................................................................................................................................................................................................................................................................................................................................................................................... 2619
2.4 Renewing crankshaft oil seal (gearbox end)................................................................................................................................................................................................................................................................................................................................................................................................................ 2621
3 Crankshaft...................................................................................................................................................................................................................................................................................................................................................................................................................................................... 2623
3.1 Exploded view - crankshaft................................................................................................................................................................................................................................................................................................................................................................................................................................ 2623
3.2 Crankshaft dimensions..................................................................................................................................................................................................................................................................................................................................................................................................................................... 2626
3.3 Measuring axial clearance of crankshaft................................................................................................................................................................................................................................................................................................................................................................................................................... 2626
3.4 Measuring radial clearance of crankshaft.................................................................................................................................................................................................................................................................................................................................................................................................................. 2627
4 Balance shaft................................................................................................................................................................................................................................................................................................................................................................................................................................................... 2629
4.1 Exploded view - balance shaft............................................................................................................................................................................................................................................................................................................................................................................................................................. 2629
4.2 Removing and installing balance shaft..................................................................................................................................................................................................................................................................................................................................................................................................................... 2629
5 Pistons and conrods............................................................................................................................................................................................................................................................................................................................................................................................................................................. 2632
5.1 Exploded view - pistons and conrods....................................................................................................................................................................................................................................................................................................................................................................................................................... 2632
5.2 Piston and cylinder dimensions............................................................................................................................................................................................................................................................................................................................................................................................................................ 2635
5.3 Checking radial clearance of conrod bearings.............................................................................................................................................................................................................................................................................................................................................................................................................. 2635
15 – Cylinder head, valve gear........................................................................................................................................................................................................................................................................................................................................................................................................................................ 2636
1 Cylinder head................................................................................................................................................................................................................................................................................................................................................................................................................................................... 2636
1.1 Exploded view - cylinder head............................................................................................................................................................................................................................................................................................................................................................................................................................. 2636
1.2 Removing and installing cylinder head..................................................................................................................................................................................................................................................................................................................................................................................................................... 2639
1.3 Removing and installing cylinder head cover (left-side)................................................................................................................................................................................................................................................................................................................................................................................................... 2658
1.4 Removing and installing cylinder head cover (right-side).................................................................................................................................................................................................................................................................................................................................................................................................. 2661
1.5 Checking compression...................................................................................................................................................................................................................................................................................................................................................................................................................................... 2664
2 Timing chain cover.............................................................................................................................................................................................................................................................................................................................................................................................................................................. 2669
2.1 Exploded view - timing chain cover........................................................................................................................................................................................................................................................................................................................................................................................................................ 2669
2.2 Removing and installing timing chain covers (left and right).............................................................................................................................................................................................................................................................................................................................................................................................. 2671
2.3 Removing and installing timing chain cover (bottom)....................................................................................................................................................................................................................................................................................................................................................................................................... 2675
3 Chain drive..................................................................................................................................................................................................................................................................................................................................................................................................................................................... 2681
3.1 Exploded view - camshaft timing chains.................................................................................................................................................................................................................................................................................................................................................................................................................... 2681
3.2 Exploded view - drive chain for valve gear................................................................................................................................................................................................................................................................................................................................................................................................................ 2683
3.3 Exploded view - drive chain for balance shaft and oil pump................................................................................................................................................................................................................................................................................................................................................................................................ 2685
3.4 Removing and installing camshaft timing chain............................................................................................................................................................................................................................................................................................................................................................................................................. 2685
3.5 Removing camshaft timing chain from camshafts............................................................................................................................................................................................................................................................................................................................................................................................................. 2687
3.6 Removing and installing drive chain for valve gear........................................................................................................................................................................................................................................................................................................................................................................................................ 2697
3.7 Removing and installing drive chain for auxiliary drive................................................................................................................................................................................................................................................................................................................................................................................................... 2698
4 Valve gear...................................................................................................................................................................................................................................................................................................................................................................................................................................................... 2702
4.1 Exploded view - valve gear................................................................................................................................................................................................................................................................................................................................................................................................................................ 2702
4.2 Measuring axial clearance of camshaft..................................................................................................................................................................................................................................................................................................................................................................................................................... 2705
4.3 Measuring radial clearance of camshaft.................................................................................................................................................................................................................................................................................................................................................................................................................... 2705
4.4 Removing and installing camshaft.......................................................................................................................................................................................................................................................................................................................................................................................................................... 2706
4.5 Checking hydraulic valve compensation elements............................................................................................................................................................................................................................................................................................................................................................................................................ 2711
4.6 Removing and installing valve stem oil seals.............................................................................................................................................................................................................................................................................................................................................................................................................. 2713
4.6.1 Renewing valve stem oil seals with cylinder head installed.......................................................................................................................................................................................................................................................................................................................................................................................... 2713
4.6.2 Renewing valve stem oil seals with cylinder head removed............................................................................................................................................................................................................................................................................................................................................................................................ 2717
5 Inlet and exhaust valves........................................................................................................................................................................................................................................................................................................................................................................................................................................ 2721
5.1 Checking valve guides..................................................................................................................................................................................................................................................................................................................................................................................................................................... 2721
5.2 Checking valves........................................................................................................................................................................................................................................................................................................................................................................................................................................... 2722
5.3 Valve dimensions.......................................................................................................................................................................................................................................................................................................................................................................................................................................... 2723
17 – Lubrication...................................................................................................................................................................................................................................................................................................................................................................................................................................................... 2724
1 Sump/oil pump................................................................................................................................................................................................................................................................................................................................................................................................................................................... 2724
1.1 Exploded view - sump/oil pump............................................................................................................................................................................................................................................................................................................................................................................................................................. 2724
1.2 Engine oil................................................................................................................................................................................................................................................................................................................................................................................................................................................ 2727
1.3 Checking engine oil level................................................................................................................................................................................................................................................................................................................................................................................................................................. 2727
1.4 Removing and installing sump (bottom section)............................................................................................................................................................................................................................................................................................................................................................................................................. 2727
1.5 Removing and installing sump (top section)................................................................................................................................................................................................................................................................................................................................................................................................................ 2730
1.6 Removing and installing oil pump.......................................................................................................................................................................................................................................................................................................................................................................................................................... 2733
1.7 Removing and installing oil level and oil temperature sender -G266-....................................................................................................................................................................................................................................................................................................................................................................................... 2733
2 Engine oil cooler............................................................................................................................................................................................................................................................................................................................................................................................................................................... 2734
2.1 Exploded view - engine oil cooler......................................................................................................................................................................................................................................................................................................................................................................................................................... 2734
2.2 Removing and installing engine oil cooler................................................................................................................................................................................................................................................................................................................................................................................................................. 2736
3 Crankcase breather.............................................................................................................................................................................................................................................................................................................................................................................................................................................. 2738
3.1 Exploded view - crankcase breather system................................................................................................................................................................................................................................................................................................................................................................................................................. 2738
3.2 Removing and installing crankcase breather hoses.......................................................................................................................................................................................................................................................................................................................................................................................................... 2739
3.3 Removing and installing oil separator..................................................................................................................................................................................................................................................................................................................................................................................................................... 2740
4 Oil filter/oil pressure switch.................................................................................................................................................................................................................................................................................................................................................................................................................................. 2741
4.1 Exploded view - oil filter/oil pressure switches.......................................................................................................................................................................................................................................................................................................................................................................................................... 2741
4.2 Removing and installing oil pressure switch -F22-......................................................................................................................................................................................................................................................................................................................................................................................................... 2743
4.3 Removing and installing oil pressure switch for reduced oil pressure -F378-............................................................................................................................................................................................................................................................................................................................................................................... 2744
4.4 Checking oil pressure and oil pressure switch............................................................................................................................................................................................................................................................................................................................................................................................................. 2744
4.5 Checking oil pressure..................................................................................................................................................................................................................................................................................................................................................................................................................................... 2744
4.6 Removing and installing oil filter housing................................................................................................................................................................................................................................................................................................................................................................................................................ 2745
4.7 Removing and installing valve for oil pressure control -N428-............................................................................................................................................................................................................................................................................................................................................................................................. 2747
19 – Cooling.......................................................................................................................................................................................................................................................................................................................................................................................................................................................... 2750
1 Cooling system/coolant.......................................................................................................................................................................................................................................................................................................................................................................................................................................... 2750
1.1 Connection diagram - coolant hoses........................................................................................................................................................................................................................................................................................................................................................................................................................ 2750
1.2 Checking cooling system for leaks......................................................................................................................................................................................................................................................................................................................................................................................................................... 2752
1.3 Draining and filling cooling system....................................................................................................................................................................................................................................................................................................................................................................................................................... 2754
2 Coolant pump/thermostat assembly................................................................................................................................................................................................................................................................................................................................................................................................................................ 2761
2.1 Exploded view - coolant pump and thermostat............................................................................................................................................................................................................................................................................................................................................................................................................... 2761
2.2 Exploded view - electric coolant pump..................................................................................................................................................................................................................................................................................................................................................................................................................... 2762
2.3 Removing and installing electrical coolant pump........................................................................................................................................................................................................................................................................................................................................................................................................... 2762
2.3.1 Removing and installing continued coolant circulation pump -V51-.................................................................................................................................................................................................................................................................................................................................................................................... 2762
2.4 Removing and installing coolant pump...................................................................................................................................................................................................................................................................................................................................................................................................................... 2764
2.5 Removing and installing thermostat........................................................................................................................................................................................................................................................................................................................................................................................................................ 2765
2.6 Checking thermostat....................................................................................................................................................................................................................................................................................................................................................................................................................................... 2765
2.7 Removing and installing coolant temperature sender -G62-.................................................................................................................................................................................................................................................................................................................................................................................................. 2766
3 Coolant pipes................................................................................................................................................................................................................................................................................................................................................................................................................................................... 2767
3.1 Exploded view - coolant pipes............................................................................................................................................................................................................................................................................................................................................................................................................................. 2767
3.2 Removing and installing coolant pipes (front)............................................................................................................................................................................................................................................................................................................................................................................................................. 2768
3.3 Removing and installing coolant pipes (left-side)......................................................................................................................................................................................................................................................................................................................................................................................................... 2771
3.4 Removing and installing coolant pipes (top)............................................................................................................................................................................................................................................................................................................................................................................................................... 2773
4 Radiator/radiator fans.......................................................................................................................................................................................................................................................................................................................................................................................................................................... 2776
4.1 Exploded view - radiator/radiator fans.................................................................................................................................................................................................................................................................................................................................................................................................................... 2776
4.2 Removing and installing radiator.......................................................................................................................................................................................................................................................................................................................................................................................................................... 2778
4.2.1 Removing and installing radiator - Audi A4.......................................................................................................................................................................................................................................................................................................................................................................................................... 2778
4.2.2 Removing and installing radiator - Audi A5.......................................................................................................................................................................................................................................................................................................................................................................................................... 2784
4.3 Removing and installing radiator cowl..................................................................................................................................................................................................................................................................................................................................................................................................................... 2789
4.4 Removing and installing radiator fan control unit -J293-.................................................................................................................................................................................................................................................................................................................................................................................................. 2793
4.5 Removing and installing radiator fans..................................................................................................................................................................................................................................................................................................................................................................................................................... 2794
24 – Mixture preparation - injection.................................................................................................................................................................................................................................................................................................................................................................................................................................. 2796
1 Injection system................................................................................................................................................................................................................................................................................................................................................................................................................................................ 2796
1.1 Overview of fitting locations - injection system.......................................................................................................................................................................................................................................................................................................................................................................................................... 2796
1.2 Reducing pressure in high-pressure section of injection system............................................................................................................................................................................................................................................................................................................................................................................................ 2806
1.3 Procedure before opening high-pressure section of injection system........................................................................................................................................................................................................................................................................................................................................................................................ 2807
1.4 Checking fuel system for leaks............................................................................................................................................................................................................................................................................................................................................................................................................................ 2811
2 Injectors....................................................................................................................................................................................................................................................................................................................................................................................................................................................... 2813
2.1 Removing and installing injectors......................................................................................................................................................................................................................................................................................................................................................................................................................... 2813
3 Air cleaner..................................................................................................................................................................................................................................................................................................................................................................................................................................................... 2817
3.1 Exploded view - air cleaner housing....................................................................................................................................................................................................................................................................................................................................................................................................................... 2817
3.2 Removing and installing air filter element................................................................................................................................................................................................................................................................................................................................................................................................................ 2818
3.3 Removing air cleaner (bottom section)..................................................................................................................................................................................................................................................................................................................................................................................................................... 2820
4 Intake manifold................................................................................................................................................................................................................................................................................................................................................................................................................................................. 2823
4.1 Exploded view - intake manifold (bottom section) with fuel rail........................................................................................................................................................................................................................................................................................................................................................................................... 2823
4.2 Exploded view - intake manifold (top section)............................................................................................................................................................................................................................................................................................................................................................................................................. 2825
4.3 Removing and installing intake manifold (bottom section) with fuel rail................................................................................................................................................................................................................................................................................................................................................................................... 2826
4.4 Removing and installing intake manifold (top section)..................................................................................................................................................................................................................................................................................................................................................................................................... 2828
5 Senders and sensors............................................................................................................................................................................................................................................................................................................................................................................................................................................. 2831
5.1 Removing and installing fuel pressure sender -G247-....................................................................................................................................................................................................................................................................................................................................................................................................... 2831
6 Engine control unit............................................................................................................................................................................................................................................................................................................................................................................................................................................. 2832
6.1 Wiring and component check with test box -V.A.G 1598/42-.................................................................................................................................................................................................................................................................................................................................................................................................. 2832
6.2 Removing and installing engine control unit -J623-........................................................................................................................................................................................................................................................................................................................................................................................................ 2834
7 High-pressure pump.............................................................................................................................................................................................................................................................................................................................................................................................................................................. 2838
7.1 Exploded view - high-pressure pump........................................................................................................................................................................................................................................................................................................................................................................................................................ 2838
7.2 Removing and installing high-pressure pump................................................................................................................................................................................................................................................................................................................................................................................................................ 2840
7.3 Removing and installing high-pressure pipe................................................................................................................................................................................................................................................................................................................................................................................................................ 2843
7.4 Checking fuel system pressurisation pump -G6-............................................................................................................................................................................................................................................................................................................................................................................................................. 2844
8 Lambda probe.................................................................................................................................................................................................................................................................................................................................................................................................................................................... 2849
8.1 Exploded view - Lambda probe.............................................................................................................................................................................................................................................................................................................................................................................................................................. 2849
8.2 Removing and installing Lambda probe...................................................................................................................................................................................................................................................................................................................................................................................................................... 2850
8.2.1 Removing and installing Lambda probe -G39- before catalytic converter - bank 1 (right-side)......................................................................................................................................................................................................................................................................................................................................................... 2850
8.2.2 Removing and installing Lambda probe after catalytic converter -G130- - bank 1 (right-side)......................................................................................................................................................................................................................................................................................................................................................... 2851
8.2.3 Removing and installing Lambda probe 2 -G108- before catalytic converter - bank 2 (left-side)....................................................................................................................................................................................................................................................................................................................................................... 2853
8.2.4 Removing and installing Lambda probe 2 after catalytic converter -G131- - bank 2 (left-side)........................................................................................................................................................................................................................................................................................................................................................ 2855
26 – Exhaust system................................................................................................................................................................................................................................................................................................................................................................................................................................................... 2858
1 Exhaust pipes/silencers......................................................................................................................................................................................................................................................................................................................................................................................................................................... 2858
1.1 Exploded view - silencers................................................................................................................................................................................................................................................................................................................................................................................................................................. 2858
1.2 Separating exhaust pipes/silencers........................................................................................................................................................................................................................................................................................................................................................................................................................ 2862
1.3 Removing and installing front silencers................................................................................................................................................................................................................................................................................................................................................................................................................... 2863
1.4 Renewing tailpipes........................................................................................................................................................................................................................................................................................................................................................................................................................................ 2864
1.5 Stress-free alignment of exhaust system................................................................................................................................................................................................................................................................................................................................................................................................................... 2865
1.6 Aligning tailpipes........................................................................................................................................................................................................................................................................................................................................................................................................................................ 2866
1.7 Checking exhaust system for leaks......................................................................................................................................................................................................................................................................................................................................................................................................................... 2866
2 Emission control system......................................................................................................................................................................................................................................................................................................................................................................................................................................... 2867
2.1 Removing and installing catalytic converter (left-side)................................................................................................................................................................................................................................................................................................................................................................................................... 2867
2.1.1 Removing and installing catalytic converter (left-side) - vehicles with manual gearbox.............................................................................................................................................................................................................................................................................................................................................................. 2867
2.1.2 Removing and installing catalytic converter (left-side) - vehicles with multitronic gearbox 0AW/automatic gearbox 0B6............................................................................................................................................................................................................................................................................................................................... 2869
2.2 Removing and installing catalytic converter (right-side).................................................................................................................................................................................................................................................................................................................................................................................................. 2870
2.2.1 Removing and installing catalytic converter (right-side) - vehicles with manual gearbox/multitronic gearbox 0AW..................................................................................................................................................................................................................................................................................................................................... 2870
2.2.2 Removing and installing catalytic converter (right-side) - vehicles with automatic gearbox 0B6...................................................................................................................................................................................................................................................................................................................................................... 2871
3 Secondary air system............................................................................................................................................................................................................................................................................................................................................................................................................................................ 2873
3.1 Exploded view - secondary air system...................................................................................................................................................................................................................................................................................................................................................................................................................... 2873
3.1.1 Exploded view - secondary air system, country-specific version 1.................................................................................................................................................................................................................................................................................................................................................................................... 2873
3.1.2 Exploded view - secondary air system, country-specific version 2.................................................................................................................................................................................................................................................................................................................................................................................... 2875
3.2 Removing and installing secondary air pump motor -V101-................................................................................................................................................................................................................................................................................................................................................................................................... 2876
3.2.1 Removing and installing secondary air pump - country-specific version 1............................................................................................................................................................................................................................................................................................................................................................................. 2876
3.2.2 Removing and installing secondary air pump - country-specific version 2............................................................................................................................................................................................................................................................................................................................................................................. 2878
3.3 Removing and installing combination valve................................................................................................................................................................................................................................................................................................................................................................................................................. 2880
3.3.1 Removing and installing combination valve for secondary air system (left-side) - country-specific version 1......................................................................................................................................................................................................................................................................................................................................... 2880
3.3.2 Removing and installing combination valve for secondary air system (right-side) - country-specific version 1........................................................................................................................................................................................................................................................................................................................................ 2881
3.3.3 Removing and installing combination valve for secondary air system (left-side) - country-specific version 2......................................................................................................................................................................................................................................................................................................................................... 2883
3.3.4 Removing and installing combination valve for secondary air system (right-side) - country-specific version 2........................................................................................................................................................................................................................................................................................................................................ 2885
3.4 Checking combination valves............................................................................................................................................................................................................................................................................................................................................................................................................................... 2886
3.4.1 Checking combination valves for secondary air system for proper operation and leakage - country-specific version 1.................................................................................................................................................................................................................................................................................................................................. 2886
3.4.2 Checking combination valves for secondary air system for proper operation and leakage - country-specific version 2.................................................................................................................................................................................................................................................................................................................................. 2887
3.5 Removing and installing sender 1 for secondary air pressure -G609-........................................................................................................................................................................................................................................................................................................................................................................................ 2889
3.5.1 Removing and installing sender 1 for secondary air pressure -G609- - country-specific version 2..................................................................................................................................................................................................................................................................................................................................................... 2889
4 Exhaust manifold................................................................................................................................................................................................................................................................................................................................................................................................................................................ 2891
4.1 Exploded view - exhaust manifold.......................................................................................................................................................................................................................................................................................................................................................................................................................... 2891
4.2 Removing and installing exhaust manifold (left-side)...................................................................................................................................................................................................................................................................................................................................................................................................... 2892
4.3 Removing and installing exhaust manifold (right-side)..................................................................................................................................................................................................................................................................................................................................................................................................... 2894
28 – Ignition system.................................................................................................................................................................................................................................................................................................................................................................................................................................................. 2896
1 Ignition system................................................................................................................................................................................................................................................................................................................................................................................................................................................. 2896
1.1 Exploded view - ignition system........................................................................................................................................................................................................................................................................................................................................................................................................................... 2896
1.2 Test data, spark plugs.................................................................................................................................................................................................................................................................................................................................................................................................................................... 2897
1.3 Removing and installing ignition coils.................................................................................................................................................................................................................................................................................................................................................................................................................... 2897
1.4 Removing and installing knock sensor...................................................................................................................................................................................................................................................................................................................................................................................................................... 2899
1.5 Removing and installing Hall senders...................................................................................................................................................................................................................................................................................................................................................................................................................... 2900
1.6 Removing and installing engine speed sender -G28-......................................................................................................................................................................................................................................................................................................................................................................................................... 2901
6-cylinder_TDI_engine_(2_7_ltr___3_0_ltr__4-valve_common_rail)............................................................................................................................................................................................................................................................................................................................................................................................................ 2902
00 – Technical data................................................................................................................................................................................................................................................................................................................................................................................................................................................... 2910
1 Identification.................................................................................................................................................................................................................................................................................................................................................................................................................................................. 2910
1.1 Engine identification number/engine data.................................................................................................................................................................................................................................................................................................................................................................................................................. 2910
2 Safety precautions.............................................................................................................................................................................................................................................................................................................................................................................................................................................. 2912
2.1 Safety precautions when working on the fuel supply system................................................................................................................................................................................................................................................................................................................................................................................................. 2912
2.2 Working on the reducing agent metering system - vehicles with SCR catalytic converter..................................................................................................................................................................................................................................................................................................................................................................... 2914
2.3 Adapting learnt value after draining reducing agent or renewing components................................................................................................................................................................................................................................................................................................................................................................................ 2915
2.4 Safety precautions when working on vehicles with start/stop system........................................................................................................................................................................................................................................................................................................................................................................................ 2915
2.5 Safety precautions when using testers and measuring instruments during a road test........................................................................................................................................................................................................................................................................................................................................................................ 2915
2.6 Safety precautions when working on the cooling system..................................................................................................................................................................................................................................................................................................................................................................................................... 2916
2.7 Safety precautions when working on the subframe........................................................................................................................................................................................................................................................................................................................................................................................................... 2916
2.8 Safety precautions when working on the exhaust system..................................................................................................................................................................................................................................................................................................................................................................................................... 2916
3 Repair instructions............................................................................................................................................................................................................................................................................................................................................................................................................................................. 2918
3.1 Rules for cleanliness..................................................................................................................................................................................................................................................................................................................................................................................................................................... 2918
3.2 General notes............................................................................................................................................................................................................................................................................................................................................................................................................................................. 2918
3.3 General repair instructions............................................................................................................................................................................................................................................................................................................................................................................................................................... 2919
3.4 Foreign particles in engine............................................................................................................................................................................................................................................................................................................................................................................................................................... 2920
3.5 Contact corrosion......................................................................................................................................................................................................................................................................................................................................................................................................................................... 2920
3.6 Routing and attachment of pipes, hoses and wiring......................................................................................................................................................................................................................................................................................................................................................................................................... 2920
3.7 Installing radiators and condensers....................................................................................................................................................................................................................................................................................................................................................................................................................... 2920
3.8 Checking vacuum system.................................................................................................................................................................................................................................................................................................................................................................................................................................... 2920
10 – Removing and installing engine................................................................................................................................................................................................................................................................................................................................................................................................................................... 2922
1 Removing and installing engine.................................................................................................................................................................................................................................................................................................................................................................................................................................. 2922
1.1 Removing engine........................................................................................................................................................................................................................................................................................................................................................................................................................................... 2922
1.1.1 Removing engine, vehicles with manual gearbox....................................................................................................................................................................................................................................................................................................................................................................................................... 2922
1.1.2 Removing engine - vehicles with multitronic gearbox 0AW............................................................................................................................................................................................................................................................................................................................................................................................. 2943
1.1.3 Removing engine, vehicles with dual clutch gearbox 0B5.............................................................................................................................................................................................................................................................................................................................................................................................. 2963
1.1.4 Removing engine - vehicles with automatic gearbox 0B6............................................................................................................................................................................................................................................................................................................................................................................................... 2982
1.2 Separating engine and gearbox............................................................................................................................................................................................................................................................................................................................................................................................................................. 3004
1.2.1 Separating engine and gearbox - manual gearbox...................................................................................................................................................................................................................................................................................................................................................................................................... 3004
1.2.2 Separating engine and gearbox, vehicles with multitronic gearbox 0AW................................................................................................................................................................................................................................................................................................................................................................................ 3010
1.2.3 Separating engine and gearbox, vehicles with dual clutch gearbox 0B5................................................................................................................................................................................................................................................................................................................................................................................ 3016
1.2.4 Separating engine and automatic gearbox 0B6......................................................................................................................................................................................................................................................................................................................................................................................................... 3023
1.3 Securing engine to engine and gearbox support............................................................................................................................................................................................................................................................................................................................................................................................................. 3030
1.4 Installing engine......................................................................................................................................................................................................................................................................................................................................................................................................................................... 3034
1.4.1 Installing engine, vehicles with manual gearbox..................................................................................................................................................................................................................................................................................................................................................................................................... 3034
1.4.2 Installing engine - vehicles with multitronic gearbox 0AW........................................................................................................................................................................................................................................................................................................................................................................................... 3042
1.4.3 Installing engine, vehicles with dual clutch gearbox 0B5............................................................................................................................................................................................................................................................................................................................................................................................ 3049
1.4.4 Installing engine - vehicles with automatic gearbox 0B6............................................................................................................................................................................................................................................................................................................................................................................................. 3056
2 Assembly mountings.............................................................................................................................................................................................................................................................................................................................................................................................................................................. 3064
2.1 Exploded view - assembly mountings........................................................................................................................................................................................................................................................................................................................................................................................................................ 3064
2.2 Removing and installing engine mountings.................................................................................................................................................................................................................................................................................................................................................................................................................. 3065
2.2.1 Removing and installing engine mounting (left-side)................................................................................................................................................................................................................................................................................................................................................................................................. 3065
2.2.2 Removing and installing engine mounting (right-side)................................................................................................................................................................................................................................................................................................................................................................................................ 3067
3 Engine cover panel.............................................................................................................................................................................................................................................................................................................................................................................................................................................. 3070
3.1 Removing and installing engine cover panel................................................................................................................................................................................................................................................................................................................................................................................................................ 3070
13 – Crankshaft group................................................................................................................................................................................................................................................................................................................................................................................................................................................. 3071
1 Cylinder block (pulley end)..................................................................................................................................................................................................................................................................................................................................................................................................................................... 3071
1.1 Exploded view - poly V-belt drive......................................................................................................................................................................................................................................................................................................................................................................................................................... 3071
1.2 Exploded view - sealing flange (pulley end)............................................................................................................................................................................................................................................................................................................................................................................................................... 3075
1.3 Removing and installing poly V-belt....................................................................................................................................................................................................................................................................................................................................................................................................................... 3076
1.4 Removing and installing tensioner for poly V-belt......................................................................................................................................................................................................................................................................................................................................................................................................... 3078
1.5 Removing and installing idler roller (left-side) for poly V-belt.......................................................................................................................................................................................................................................................................................................................................................................................... 3078
1.6 Removing and installing vibration damper.................................................................................................................................................................................................................................................................................................................................................................................................................. 3079
1.7 Removing and installing bracket for ancillaries........................................................................................................................................................................................................................................................................................................................................................................................................... 3079
1.8 Renewing crankshaft oil seal (pulley end)................................................................................................................................................................................................................................................................................................................................................................................................................. 3079
1.9 Removing and installing sealing flange (pulley end)....................................................................................................................................................................................................................................................................................................................................................................................................... 3081
2 Cylinder block (gearbox end).................................................................................................................................................................................................................................................................................................................................................................................................................................... 3084
2.1 Exploded view - drive plate............................................................................................................................................................................................................................................................................................................................................................................................................................... 3084
2.2 Removing and installing drive plate....................................................................................................................................................................................................................................................................................................................................................................................................................... 3085
2.3 Removing and installing sender wheel...................................................................................................................................................................................................................................................................................................................................................................................................................... 3086
2.4 Checking sender wheel..................................................................................................................................................................................................................................................................................................................................................................................................................................... 3087
2.5 Renewing crankshaft oil seal (gearbox end)................................................................................................................................................................................................................................................................................................................................................................................................................ 3088
2.6 Renewing needle bearing in drive plate.................................................................................................................................................................................................................................................................................................................................................................................................................... 3089
3 Crankshaft...................................................................................................................................................................................................................................................................................................................................................................................................................................................... 3092
3.1 Exploded view - crankshaft................................................................................................................................................................................................................................................................................................................................................................................................................................ 3092
3.2 Crankshaft dimensions..................................................................................................................................................................................................................................................................................................................................................................................................................................... 3094
3.3 Measuring axial clearance of crankshaft................................................................................................................................................................................................................................................................................................................................................................................................................... 3094
3.4 Measuring radial clearance of crankshaft.................................................................................................................................................................................................................................................................................................................................................................................................................. 3095
4 Balance shaft................................................................................................................................................................................................................................................................................................................................................................................................................................................... 3096
4.1 Removing and installing balance shaft..................................................................................................................................................................................................................................................................................................................................................................................................................... 3096
5 Pistons and conrods............................................................................................................................................................................................................................................................................................................................................................................................................................................. 3098
5.1 Exploded view - pistons and conrods....................................................................................................................................................................................................................................................................................................................................................................................................................... 3098
5.2 Measuring piston projection at TDC........................................................................................................................................................................................................................................................................................................................................................................................................................ 3101
5.3 Checking pistons and cylinder bores....................................................................................................................................................................................................................................................................................................................................................................................................................... 3103
5.4 Checking radial clearance of conrod bearings.............................................................................................................................................................................................................................................................................................................................................................................................................. 3103
15 – Cylinder head, valve gear........................................................................................................................................................................................................................................................................................................................................................................................................................................ 3104
1 Cylinder head................................................................................................................................................................................................................................................................................................................................................................................................................................................... 3104
1.1 Exploded view - cylinder head............................................................................................................................................................................................................................................................................................................................................................................................................................. 3104
1.2 Exploded view - cylinder head cover....................................................................................................................................................................................................................................................................................................................................................................................................................... 3106
1.3 Removing and installing cylinder head..................................................................................................................................................................................................................................................................................................................................................................................................................... 3107
1.3.1 Removing cylinder head - engine codes CAMA, CAMB, CCLA, CCWA, CCWB, CGKA, CGKB...................................................................................................................................................................................................................................................................................................................................................................... 3107
1.3.2 Removing cylinder head - engine code CAPA........................................................................................................................................................................................................................................................................................................................................................................................................... 3112
1.3.3 Installing cylinder head............................................................................................................................................................................................................................................................................................................................................................................................................................ 3118
1.4 Removing and installing cylinder head cover............................................................................................................................................................................................................................................................................................................................................................................................................... 3123
1.4.1 Removing and installing cylinder head cover (left-side)............................................................................................................................................................................................................................................................................................................................................................................................. 3123
1.4.2 Removing and installing cylinder head cover (right-side)............................................................................................................................................................................................................................................................................................................................................................................................ 3128
1.5 Checking compression...................................................................................................................................................................................................................................................................................................................................................................................................................................... 3132
2 Timing chain cover.............................................................................................................................................................................................................................................................................................................................................................................................................................................. 3135
2.1 Exploded view - timing chain cover........................................................................................................................................................................................................................................................................................................................................................................................................................ 3135
2.2 Removing and installing timing chain cover................................................................................................................................................................................................................................................................................................................................................................................................................ 3137
2.2.1 Removing and installing timing chain cover (left-side).............................................................................................................................................................................................................................................................................................................................................................................................. 3137
2.2.2 Removing and installing timing chain cover (right-side)............................................................................................................................................................................................................................................................................................................................................................................................. 3139
2.2.3 Removing and installing timing chain cover (bottom)................................................................................................................................................................................................................................................................................................................................................................................................. 3141
3 Chain drive..................................................................................................................................................................................................................................................................................................................................................................................................................................................... 3144
3.1 Exploded view - camshaft timing chains.................................................................................................................................................................................................................................................................................................................................................................................................................... 3144
3.1.1 Exploded view - camshaft timing chains, engine codes CAMA, CAMB, CCLA, CCWA, CCWB, CGKA, CGKB....................................................................................................................................................................................................................................................................................................................................................... 3144
3.1.2 Exploded view - camshaft timing chains, engine code CAPA............................................................................................................................................................................................................................................................................................................................................................................................ 3147
3.2 Exploded view - drive chain for valve gear................................................................................................................................................................................................................................................................................................................................................................................................................ 3149
3.2.1 Exploded view - drive chain for valve gear, engine codes CAMA, CAMB, CCLA, CCWA, CCWB, CGKA, CGKB................................................................................................................................................................................................................................................................................................................................................... 3149
3.2.2 Exploded view - drive chain for valve gear, engine code CAPA........................................................................................................................................................................................................................................................................................................................................................................................ 3150
3.3 Exploded view - drive chain for balance shaft and oil pump................................................................................................................................................................................................................................................................................................................................................................................................ 3152
3.4 Exploded view - drive chain for balance shaft............................................................................................................................................................................................................................................................................................................................................................................................................. 3153
3.5 Removing and installing camshaft timing chain............................................................................................................................................................................................................................................................................................................................................................................................................. 3154
3.5.1 Removing and installing camshaft timing chain - engine codes CAMA, CAMB, CCLA, CCWA, CCWB, CGKA, CGKB............................................................................................................................................................................................................................................................................................................................................... 3154
3.5.2 Removing and installing camshaft timing chain - engine code CAPA.................................................................................................................................................................................................................................................................................................................................................................................... 3162
3.6 Removing camshaft timing chain from camshafts............................................................................................................................................................................................................................................................................................................................................................................................................. 3171
3.6.1 Removing camshaft timing chain from camshafts - engine codes CAMA, CAMB, CCLA, CCWA, CCWB, CGKA, CGKB............................................................................................................................................................................................................................................................................................................................................... 3171
3.6.2 Removing camshaft timing chain from camshafts - engine code CAPA.................................................................................................................................................................................................................................................................................................................................................................................... 3180
3.7 Removing and installing drive chain for valve gear........................................................................................................................................................................................................................................................................................................................................................................................................ 3189
3.7.1 Removing and installing drive chain for valve gear - engine codes CAMA, CAMB, CCLA, CCWA, CCWB, CGKA, CGKB.......................................................................................................................................................................................................................................................................................................................................... 3189
3.7.2 Removing and installing drive chain for valve gear - engine code CAPA............................................................................................................................................................................................................................................................................................................................................................................... 3191
3.8 Removing and installing drive chain for auxiliary drive................................................................................................................................................................................................................................................................................................................................................................................................... 3192
4 Valve gear...................................................................................................................................................................................................................................................................................................................................................................................................................................................... 3196
4.1 Exploded view - valve gear................................................................................................................................................................................................................................................................................................................................................................................................................................ 3196
4.2 Measuring axial clearance of camshaft..................................................................................................................................................................................................................................................................................................................................................................................................................... 3198
4.3 Measuring radial clearance of camshaft.................................................................................................................................................................................................................................................................................................................................................................................................................... 3199
4.4 Removing and installing camshaft oil seal................................................................................................................................................................................................................................................................................................................................................................................................................. 3200
4.5 Removing and installing camshaft.......................................................................................................................................................................................................................................................................................................................................................................................................................... 3202
4.5.1 Removing and installing camshaft - cylinder head (left-side)........................................................................................................................................................................................................................................................................................................................................................................................ 3202
4.5.2 Removing and installing camshaft - cylinder head (right-side)....................................................................................................................................................................................................................................................................................................................................................................................... 3210
4.6 Checking hydraulic valve compensation elements............................................................................................................................................................................................................................................................................................................................................................................................................ 3217
4.7 Removing and installing valve stem oil seals.............................................................................................................................................................................................................................................................................................................................................................................................................. 3219
4.7.1 Removing and installing valve stem oil seals with cylinder head installed........................................................................................................................................................................................................................................................................................................................................................................... 3219
4.7.2 Removing and installing valve stem oil seals with cylinder head removed............................................................................................................................................................................................................................................................................................................................................................................. 3223
5 Inlet and exhaust valves........................................................................................................................................................................................................................................................................................................................................................................................................................................ 3226
5.1 Machining valve seats..................................................................................................................................................................................................................................................................................................................................................................................................................................... 3226
5.2 Checking valve guides..................................................................................................................................................................................................................................................................................................................................................................................................................................... 3226
5.3 Checking valves........................................................................................................................................................................................................................................................................................................................................................................................................................................... 3227
5.4 Valve dimensions.......................................................................................................................................................................................................................................................................................................................................................................................................................................... 3228
17 – Lubrication...................................................................................................................................................................................................................................................................................................................................................................................................................................................... 3229
1 Sump/oil pump................................................................................................................................................................................................................................................................................................................................................................................................................................................... 3229
1.1 Exploded view - sump/oil pump............................................................................................................................................................................................................................................................................................................................................................................................................................. 3229
1.2 Engine oil................................................................................................................................................................................................................................................................................................................................................................................................................................................ 3233
1.3 Checking oil level........................................................................................................................................................................................................................................................................................................................................................................................................................................ 3234
1.4 Removing and installing sump (bottom section)............................................................................................................................................................................................................................................................................................................................................................................................................. 3234
1.5 Removing and installing sump (top section)................................................................................................................................................................................................................................................................................................................................................................................................................ 3236
1.6 Removing and installing oil pump.......................................................................................................................................................................................................................................................................................................................................................................................................................... 3239
1.7 Removing and installing oil level and oil temperature sender -G266-....................................................................................................................................................................................................................................................................................................................................................................................... 3241
2 Engine oil cooler............................................................................................................................................................................................................................................................................................................................................................................................................................................... 3242
2.1 Exploded view - engine oil cooler......................................................................................................................................................................................................................................................................................................................................................................................................................... 3242
2.2 Removing and installing engine oil cooler................................................................................................................................................................................................................................................................................................................................................................................................................. 3244
2.3 Removing and installing mounting plate for engine oil cooler, pressure control valve and oil filter housing............................................................................................................................................................................................................................................................................................................................................... 3246
3 Crankcase breather.............................................................................................................................................................................................................................................................................................................................................................................................................................................. 3248
3.1 Removing and installing pressure control valve for crankcase breather system.............................................................................................................................................................................................................................................................................................................................................................................. 3248
4 Oil filter/oil pressure switches................................................................................................................................................................................................................................................................................................................................................................................................................................ 3249
4.1 Removing and installing oil pressure switch -F22-......................................................................................................................................................................................................................................................................................................................................................................................................... 3249
4.2 Removing and installing oil pressure switch -F1-.......................................................................................................................................................................................................................................................................................................................................................................................................... 3250
4.3 Removing and installing oil pressure switch -F1-/oil pressure switch for reduced oil pressure -F378-...................................................................................................................................................................................................................................................................................................................................................... 3251
4.4 Checking oil pressure..................................................................................................................................................................................................................................................................................................................................................................................................................................... 3252
4.5 Removing and installing oil filter housing................................................................................................................................................................................................................................................................................................................................................................................................................ 3253
4.6 Removing and installing valve for oil pressure control -N428-............................................................................................................................................................................................................................................................................................................................................................................................. 3255
4.7 Checking oil pressure switch -F1-/oil pressure switch -F22-/oil pressure switch for reduced oil pressure -F378-........................................................................................................................................................................................................................................................................................................................................... 3255
19 – Cooling.......................................................................................................................................................................................................................................................................................................................................................................................................................................................... 3256
1 Cooling system/coolant.......................................................................................................................................................................................................................................................................................................................................................................................................................................... 3256
1.1 Connection diagram - coolant hoses........................................................................................................................................................................................................................................................................................................................................................................................................................ 3256
1.1.1 Connection diagram - coolant hoses, vehicles without auxiliary heater............................................................................................................................................................................................................................................................................................................................................................................... 3256
1.1.2 Connection diagram - coolant hoses, vehicles with auxiliary heater.................................................................................................................................................................................................................................................................................................................................................................................. 3257
1.2 Checking cooling system for leaks......................................................................................................................................................................................................................................................................................................................................................................................................................... 3258
1.3 Draining and filling cooling system....................................................................................................................................................................................................................................................................................................................................................................................................................... 3260
2 Coolant pump/thermostat assembly................................................................................................................................................................................................................................................................................................................................................................................................................................ 3268
2.1 Exploded view - coolant pump and thermostat............................................................................................................................................................................................................................................................................................................................................................................................................... 3268
2.1.1 Exploded view - coolant pump and thermostat, vehicles without SCR catalytic converter............................................................................................................................................................................................................................................................................................................................................................... 3268
2.1.2 Exploded view - coolant pump and thermostat, vehicles with SCR catalytic converter.................................................................................................................................................................................................................................................................................................................................................................. 3270
2.2 Exploded view - electric coolant pump..................................................................................................................................................................................................................................................................................................................................................................................................................... 3271
2.3 Removing and installing electric coolant pump............................................................................................................................................................................................................................................................................................................................................................................................................. 3271
2.4 Removing and installing coolant pump...................................................................................................................................................................................................................................................................................................................................................................................................................... 3273
2.5 Removing and installing thermostat........................................................................................................................................................................................................................................................................................................................................................................................................................ 3274
2.5.1 Removing and installing thermostat - vehicles without SCR catalytic converter....................................................................................................................................................................................................................................................................................................................................................................... 3274
2.5.2 Removing and installing thermostat - vehicles with SCR catalytic converter.......................................................................................................................................................................................................................................................................................................................................................................... 3275
2.5.3 Removing and installing thermostat for exhaust gas recirculation - vehicles with SCR catalytic converter............................................................................................................................................................................................................................................................................................................................................ 3276
2.6 Removing and installing coolant temperature sender -G62-.................................................................................................................................................................................................................................................................................................................................................................................................. 3277
2.7 Removing and installing radiator outlet coolant temperature sender -G83-.................................................................................................................................................................................................................................................................................................................................................................................. 3279
3 Coolant pipes................................................................................................................................................................................................................................................................................................................................................................................................................................................... 3280
3.1 Exploded view - coolant pipes............................................................................................................................................................................................................................................................................................................................................................................................................................. 3280
3.1.1 Exploded view - coolant pipes, engine codes CAMA, CAMB, CAPA........................................................................................................................................................................................................................................................................................................................................................................................ 3280
3.1.2 Exploded view - coolant pipes, engine codes CCLA, CCWA, CCWB, CGKA, CGKB (part 1)................................................................................................................................................................................................................................................................................................................................................................... 3282
3.1.3 Exploded view - coolant pipes, engine codes CCLA, CCWA, CCWB, CGKA, CGKB (part 2)................................................................................................................................................................................................................................................................................................................................................................... 3284
3.2 Removing and installing coolant pipes..................................................................................................................................................................................................................................................................................................................................................................................................................... 3286
3.2.1 Removing and installing coolant pipe (top).......................................................................................................................................................................................................................................................................................................................................................................................................... 3286
3.2.2 Removing and installing coolant pipe (front) - engine codes CAMA, CAMB, CCLA, CCWA, CCWB, CGKA, CGKB................................................................................................................................................................................................................................................................................................................................................ 3287
3.2.3 Removing and installing coolant pipe (front) - engine code CAPA..................................................................................................................................................................................................................................................................................................................................................................................... 3289
3.2.4 Removing and installing coolant pipe (left-side).................................................................................................................................................................................................................................................................................................................................................................................................... 3293
3.2.5 Removing and installing coolant pipe (rear left) - engine codes CAMA, CAMB, CAPA.................................................................................................................................................................................................................................................................................................................................................................... 3296
3.2.6 Removing and installing coolant pipe (rear left) - engine codes CCLA, CCWA, CCWB, CGKA, CGKB........................................................................................................................................................................................................................................................................................................................................................ 3297
3.2.7 Removing and installing coolant pipe (top left) - engine codes CCWA, CCWB, CGKA, CGKB............................................................................................................................................................................................................................................................................................................................................................... 3299
3.2.8 Removing and installing coolant pipe (top left) - vehicles with SCR catalytic converter............................................................................................................................................................................................................................................................................................................................................................. 3301
3.2.9 Removing and installing coolant pipe (top right).................................................................................................................................................................................................................................................................................................................................................................................................... 3301
3.2.10 Removing and installing coolant pipe (bottom right)................................................................................................................................................................................................................................................................................................................................................................................................ 3302
3.2.11 Removing and installing coolant pipe (rear right) - engine codes CAMA, CAMB, CAPA.................................................................................................................................................................................................................................................................................................................................................................. 3305
3.2.12 Removing and installing coolant pipe (rear right) - engine codes CCLA, CCWA, CCWB, CGKA, CGKB...................................................................................................................................................................................................................................................................................................................................................... 3307
4 Radiator/radiator fans.......................................................................................................................................................................................................................................................................................................................................................................................................................................... 3309
4.1 Exploded view - radiator cowl and radiator fans........................................................................................................................................................................................................................................................................................................................................................................................................... 3309
4.2 Removing and installing radiator.......................................................................................................................................................................................................................................................................................................................................................................................................................... 3311
4.3 Removing and installing radiator cowl..................................................................................................................................................................................................................................................................................................................................................................................................................... 3317
4.4 Removing and installing radiator fan control unit......................................................................................................................................................................................................................................................................................................................................................................................................... 3323
4.5 Removing and installing radiator fans..................................................................................................................................................................................................................................................................................................................................................................................................................... 3324
21 – Turbocharging/supercharging...................................................................................................................................................................................................................................................................................................................................................................................................................................... 3326
1 Turbocharger.................................................................................................................................................................................................................................................................................................................................................................................................................................................... 3326
1.1 Exploded view - turbocharger.............................................................................................................................................................................................................................................................................................................................................................................................................................. 3326
1.2 Removing and installing turbocharger...................................................................................................................................................................................................................................................................................................................................................................................................................... 3328
1.3 Removing and installing turbocharger control unit -J724-.................................................................................................................................................................................................................................................................................................................................................................................................. 3334
1.4 Removing and installing intermediate flange............................................................................................................................................................................................................................................................................................................................................................................................................... 3346
2 Charge air system............................................................................................................................................................................................................................................................................................................................................................................................................................................... 3347
2.1 Exploded view - charge air system......................................................................................................................................................................................................................................................................................................................................................................................................................... 3347
2.2 Removing and installing charge air cooler................................................................................................................................................................................................................................................................................................................................................................................................................. 3348
2.3 Removing and installing charge pressure sender -G31-...................................................................................................................................................................................................................................................................................................................................................................................................... 3351
23 – Mixture preparation - injection.................................................................................................................................................................................................................................................................................................................................................................................................................................. 3352
1 Injection system................................................................................................................................................................................................................................................................................................................................................................................................................................................ 3352
1.1 Overview - fuel system.................................................................................................................................................................................................................................................................................................................................................................................................................................... 3352
1.2 Overview of fitting locations - injection system.......................................................................................................................................................................................................................................................................................................................................................................................................... 3355
1.2.1 Overview of fitting locations - injection system, engine codes CAMA, CAMB, CCWA, CCWB, CGKA, CGKB................................................................................................................................................................................................................................................................................................................................................... 3355
1.2.2 Overview of fitting locations - injection system, engine code CAPA.................................................................................................................................................................................................................................................................................................................................................................................. 3364
1.3 Exploded view - fuel system............................................................................................................................................................................................................................................................................................................................................................................................................................... 3374
1.3.1 Exploded view - fuel system, engine codes CAMA, CAMB, CCWA, CCWB, CGKA, CGKB, CCLA.................................................................................................................................................................................................................................................................................................................................................................. 3374
1.3.2 Exploded view - fuel system, engine code CAPA....................................................................................................................................................................................................................................................................................................................................................................................................... 3377
1.4 Filling and bleeding fuel system.......................................................................................................................................................................................................................................................................................................................................................................................................................... 3380
1.4.1 Bleeding fuel system - engine codes CAMA, CAMB, CCWA, CCWB, CGKA, CGKB, CCLA........................................................................................................................................................................................................................................................................................................................................................................ 3380
1.4.2 Performing first fuel filling after installing high-pressure pump - engine codes CAMA, CAMB, CCWA, CCWB, CGKA, CGKB, CCLA........................................................................................................................................................................................................................................................................................................................... 3381
1.5 Checking fuel system for leaks............................................................................................................................................................................................................................................................................................................................................................................................................................ 3382
2 Air cleaner..................................................................................................................................................................................................................................................................................................................................................................................................................................................... 3383
2.1 Exploded view - air cleaner housing....................................................................................................................................................................................................................................................................................................................................................................................................................... 3383
2.2 Removing and installing air filter element................................................................................................................................................................................................................................................................................................................................................................................................................ 3385
2.3 Removing and installing air cleaner housing............................................................................................................................................................................................................................................................................................................................................................................................................... 3386
3 Intake manifold................................................................................................................................................................................................................................................................................................................................................................................................................................................. 3389
3.1 Exploded view - intake manifold........................................................................................................................................................................................................................................................................................................................................................................................................................... 3389
3.2 Removing and installing intake manifold (top section)..................................................................................................................................................................................................................................................................................................................................................................................................... 3390
3.3 Removing and installing intake manifold (bottom section).................................................................................................................................................................................................................................................................................................................................................................................................. 3392
3.3.1 Removing and installing intake manifold (bottom section, left-side)................................................................................................................................................................................................................................................................................................................................................................................. 3392
3.3.2 Removing and installing intake manifold (bottom section, right-side)................................................................................................................................................................................................................................................................................................................................................................................ 3395
4 Injectors/high-pressure reservoir (rail)........................................................................................................................................................................................................................................................................................................................................................................................................................ 3398
4.1 Checking injectors........................................................................................................................................................................................................................................................................................................................................................................................................................................ 3398
4.2 Performing adaption of correction values for injectors.................................................................................................................................................................................................................................................................................................................................................................................................... 3398
4.3 Checking for injectors sticking open...................................................................................................................................................................................................................................................................................................................................................................................................................... 3399
4.4 Checking return flow rate of injectors with engine running................................................................................................................................................................................................................................................................................................................................................................................................ 3401
4.5 Checking return flow rate of injectors at starter cranking speed.......................................................................................................................................................................................................................................................................................................................................................................................... 3404
4.6 Checking pressure retention valve in fuel return line..................................................................................................................................................................................................................................................................................................................................................................................................... 3406
4.7 Checking restrictor in fuel return line................................................................................................................................................................................................................................................................................................................................................................................................................... 3407
4.8 Removing and installing injectors......................................................................................................................................................................................................................................................................................................................................................................................................................... 3408
4.9 Removing and installing high-pressure pipes............................................................................................................................................................................................................................................................................................................................................................................................................... 3413
5 High-pressure pump.............................................................................................................................................................................................................................................................................................................................................................................................................................................. 3416
5.1 Exploded view - high-pressure pump........................................................................................................................................................................................................................................................................................................................................................................................................................ 3416
5.1.1 Exploded view - high-pressure pump, engine codes CAMA, CAMB, CCWA, CCWB, CGKA, CGKB, CCLA........................................................................................................................................................................................................................................................................................................................................................... 3416
5.1.2 Exploded view - high-pressure pump, engine code CAPA................................................................................................................................................................................................................................................................................................................................................................................................ 3419
5.1.3 Exploded view - toothed belt for high-pressure pump, engine codes CAMA, CAMB, CCWA, CCWB, CGKA, CGKB, CCLA.......................................................................................................................................................................................................................................................................................................................................... 3421
5.1.4 Exploded view - toothed belt for high-pressure pump, engine code CAPA............................................................................................................................................................................................................................................................................................................................................................................... 3423
5.2 Removing and installing high-pressure pump................................................................................................................................................................................................................................................................................................................................................................................................................ 3425
5.2.1 Removing and installing high-pressure pump - engine codes CAMA, CAMB, CCWA, CCWB, CGKA, CGKB, CCLA.................................................................................................................................................................................................................................................................................................................................................. 3425
5.2.2 Removing and installing high-pressure pump - engine code CAPA....................................................................................................................................................................................................................................................................................................................................................................................... 3427
5.2.3 Removing and installing toothed belt for high-pressure pump - engine codes CAMA, CAMB, CCWA, CCWB, CGKA, CGKB, CCLA................................................................................................................................................................................................................................................................................................................................. 3430
5.2.4 Removing and installing toothed belt for high-pressure pump - engine code CAPA...................................................................................................................................................................................................................................................................................................................................................................... 3438
6 Senders and sensors............................................................................................................................................................................................................................................................................................................................................................................................................................................. 3443
6.1 Checking fuel pressure regulating valve -N276-............................................................................................................................................................................................................................................................................................................................................................................................................ 3443
6.2 Removing and installing fuel pressure regulating valve -N276-............................................................................................................................................................................................................................................................................................................................................................................................. 3445
6.3 Removing and installing fuel pressure sender -G247-....................................................................................................................................................................................................................................................................................................................................................................................................... 3447
6.4 Removing and installing air mass meter -G70-.............................................................................................................................................................................................................................................................................................................................................................................................................. 3450
6.5 Removing and installing pressure differential sender -G505-............................................................................................................................................................................................................................................................................................................................................................................................... 3450
6.6 Removing and installing exhaust gas pressure sensor 1 -G450-.............................................................................................................................................................................................................................................................................................................................................................................................. 3451
6.7 Removing and installing control unit for NOx sender -J583- with NOx sender -G295- - engine codes CAMA, CAMB, CCWA, CCWB, CGKA, CGKB, CAPA................................................................................................................................................................................................................................................................................................................. 3452
6.8 Removing and installing control unit for NOx sender 2 -J881- with NOx sender 2 -G687- - engine code CCLA.................................................................................................................................................................................................................................................................................................................................................. 3453
7 Lambda probe.................................................................................................................................................................................................................................................................................................................................................................................................................................................... 3454
7.1 Exploded view - Lambda probe.............................................................................................................................................................................................................................................................................................................................................................................................................................. 3454
7.1.1 Exploded view - Lambda probe, engine codes CAMA, CAMB, CCWA, CCWB, CGKA, CGKB, CAPA................................................................................................................................................................................................................................................................................................................................................................. 3454
7.1.2 Exploded view - Lambda probe, engine code CCLA...................................................................................................................................................................................................................................................................................................................................................................................................... 3456
7.2 Removing and installing Lambda probe...................................................................................................................................................................................................................................................................................................................................................................................................................... 3457
7.2.1 Removing and installing Lambda probe - engine codes CAMA, CAMB, CCWA, CCWB, CGKA, CGKB, CAPA........................................................................................................................................................................................................................................................................................................................................................ 3457
7.2.2 Removing and installing Lambda probe - engine code CCLA............................................................................................................................................................................................................................................................................................................................................................................................. 3458
8 Engine control unit............................................................................................................................................................................................................................................................................................................................................................................................................................................. 3460
8.1 Wiring and component check with test box -V.A.G 1598/42-.................................................................................................................................................................................................................................................................................................................................................................................................. 3460
8.2 Removing and installing engine control unit -J623-........................................................................................................................................................................................................................................................................................................................................................................................................ 3462
26 – Exhaust system................................................................................................................................................................................................................................................................................................................................................................................................................................................... 3466
1 Exhaust pipes/silencers......................................................................................................................................................................................................................................................................................................................................................................................................................................... 3466
1.1 Exploded view - silencers................................................................................................................................................................................................................................................................................................................................................................................................................................. 3466
1.1.1 Exploded view - silencers, vehicles without SCR catalytic converter................................................................................................................................................................................................................................................................................................................................................................................. 3466
1.1.2 Exploded view - silencers, vehicles with SCR catalytic converter.................................................................................................................................................................................................................................................................................................................................................................................... 3468
1.2 Removing and installing front exhaust pipe................................................................................................................................................................................................................................................................................................................................................................................................................ 3472
1.2.1 Removing and installing front exhaust pipe - A5 up to vehicle identification no. 8T-8-009 998....................................................................................................................................................................................................................................................................................................................................................... 3472
1.2.2 Removing and installing front exhaust pipe - A4 (all), A5 from vehicle identification no. 8T-8-009 999 onwards...................................................................................................................................................................................................................................................................................................................................... 3473
1.3 Separating exhaust pipes/silencers........................................................................................................................................................................................................................................................................................................................................................................................................................ 3476
1.3.1 Separating Y-pipe and rear silencers - vehicles without SCR catalytic converter..................................................................................................................................................................................................................................................................................................................................................................... 3476
1.3.2 Renewing tailpipe - vehicles without SCR catalytic converter........................................................................................................................................................................................................................................................................................................................................................................................ 3478
1.3.3 Renewing tailpipes - vehicles with SCR catalytic converter.......................................................................................................................................................................................................................................................................................................................................................................................... 3478
1.4 Stress-free alignment of exhaust system................................................................................................................................................................................................................................................................................................................................................................................................................... 3479
1.4.1 Stress-free alignment of exhaust system - vehicles without SCR catalytic converter.................................................................................................................................................................................................................................................................................................................................................................. 3479
1.4.2 Stress-free alignment of exhaust system - vehicles with SCR catalytic converter..................................................................................................................................................................................................................................................................................................................................................................... 3481
1.5 Checking exhaust system for leaks......................................................................................................................................................................................................................................................................................................................................................................................................................... 3481
2 Emission control system......................................................................................................................................................................................................................................................................................................................................................................................................................................... 3482
2.1 Removing and installing catalytic converter............................................................................................................................................................................................................................................................................................................................................................................................................... 3482
2.2 Removing and installing particulate filter................................................................................................................................................................................................................................................................................................................................................................................................................ 3483
2.2.1 Removing and installing particulate filter - A5 up to vehicle identification no. 8T-8-009 998....................................................................................................................................................................................................................................................................................................................................................... 3483
2.2.2 Removing and installing particulate filter - A4 (all), A5 from vehicle identification no. 8T-8-009 999 onwards...................................................................................................................................................................................................................................................................................................................................... 3485
3 SCR (selective catalytic reduction) system...................................................................................................................................................................................................................................................................................................................................................................................................................... 3489
3.1 Exploded view - reducing agent tank....................................................................................................................................................................................................................................................................................................................................................................................................................... 3489
3.1.1 Exploded view - active tank for reducing agent with attached components............................................................................................................................................................................................................................................................................................................................................................................. 3489
3.1.2 Exploded view - passive tank for reducing agent with attached components............................................................................................................................................................................................................................................................................................................................................................................ 3491
3.2 Exploded view - delivery unit for reducing agent.......................................................................................................................................................................................................................................................................................................................................................................................................... 3493
3.3 Exploded view - pump for reducing agent -V437-............................................................................................................................................................................................................................................................................................................................................................................................................ 3494
3.4 Exploded view - injector for reducing agent -N474-........................................................................................................................................................................................................................................................................................................................................................................................................ 3496
3.5 Exploded view - control unit for reducing agent metering system........................................................................................................................................................................................................................................................................................................................................................................................... 3497
3.6 Removing and installing delivery unit for reducing agent.................................................................................................................................................................................................................................................................................................................................................................................................. 3497
3.7 Removing and installing injector for reducing agent -N474-................................................................................................................................................................................................................................................................................................................................................................................................ 3500
3.8 Draining active tank for reducing agent................................................................................................................................................................................................................................................................................................................................................................................................................... 3501
3.9 Removing and installing active tank for reducing agent.................................................................................................................................................................................................................................................................................................................................................................................................... 3503
3.10 Draining passive tank for reducing agent................................................................................................................................................................................................................................................................................................................................................................................................................. 3505
3.11 Removing and installing passive tank for reducing agent.................................................................................................................................................................................................................................................................................................................................................................................................. 3507
3.12 Removing and installing pump for reducing agent -V437-................................................................................................................................................................................................................................................................................................................................................................................................... 3509
3.13 Removing and installing transfer pump for reducing agent -V436-.......................................................................................................................................................................................................................................................................................................................................................................................... 3510
3.14 Checking control unit for reducing agent metering system -J880-.......................................................................................................................................................................................................................................................................................................................................................................................... 3512
3.15 Removing and installing control unit for reducing agent metering system -J880-........................................................................................................................................................................................................................................................................................................................................................................... 3512
3.16 Adapting learnt value after draining reducing agent or renewing components............................................................................................................................................................................................................................................................................................................................................................................... 3513
4 Exhaust gas temperature control................................................................................................................................................................................................................................................................................................................................................................................................................................. 3514
4.1 Exploded view - exhaust gas temperature control........................................................................................................................................................................................................................................................................................................................................................................................................... 3514
4.1.1 Exploded view - exhaust gas temperature control, vehicles without SCR catalytic converter........................................................................................................................................................................................................................................................................................................................................................... 3514
4.1.2 Exploded view - exhaust gas temperature control, vehicles with SCR catalytic converter.............................................................................................................................................................................................................................................................................................................................................................. 3516
4.2 Removing and installing exhaust gas temperature sender.................................................................................................................................................................................................................................................................................................................................................................................................... 3517
4.2.1 Removing and installing exhaust gas temperature sender 1 -G235- - engine codes CAPA, CCLA, CCWA, CCWB, CGKA, CGKB................................................................................................................................................................................................................................................................................................................................... 3517
4.2.2 Removing and installing exhaust gas temperature sender -G448-/-G495-................................................................................................................................................................................................................................................................................................................................................................................ 3519
4.2.3 Removing and installing exhaust gas temperature sender -G496-/-G648-................................................................................................................................................................................................................................................................................................................................................................................ 3519
5 Exhaust gas recirculation....................................................................................................................................................................................................................................................................................................................................................................................................................................... 3521
5.1 Exploded view - exhaust gas recirculation system.......................................................................................................................................................................................................................................................................................................................................................................................................... 3521
5.1.1 Exploded view - exhaust gas recirculation system, engine codes CAMA, CAMB, CAPA..................................................................................................................................................................................................................................................................................................................................................................... 3521
5.1.2 Exploded view - exhaust gas recirculation system, engine codes CCLA, CCWA, CCWB, CGKA, CGKB......................................................................................................................................................................................................................................................................................................................................................... 3523
5.2 Removing and installing exhaust gas recirculation control motor -V338-.................................................................................................................................................................................................................................................................................................................................................................................... 3524
5.2.1 Removing and installing exhaust gas recirculation control motor -V338- - engine codes CAMA, CAMB, CAPA.............................................................................................................................................................................................................................................................................................................................................. 3524
5.2.2 Removing and installing exhaust gas recirculation control motor -V338- - engine codes CCLA, CCWA, CCWB, CGKA, CGKB.................................................................................................................................................................................................................................................................................................................................. 3526
5.3 Removing and installing exhaust gas recirculation cooler.................................................................................................................................................................................................................................................................................................................................................................................................. 3528
5.3.1 Removing and installing exhaust gas recirculation cooler - engine codes CAMA, CAMB, CAPA............................................................................................................................................................................................................................................................................................................................................................ 3528
5.3.2 Removing and installing exhaust gas recirculation cooler - engine codes CCLA, CCWA, CCWB, CGKA, CGKB................................................................................................................................................................................................................................................................................................................................................ 3530
5.4 Removing and installing exhaust gas recirculation temperature sensor -G98-................................................................................................................................................................................................................................................................................................................................................................................ 3532
6 Exhaust manifolds............................................................................................................................................................................................................................................................................................................................................................................................................................................... 3534
6.1 Exploded view - exhaust manifold.......................................................................................................................................................................................................................................................................................................................................................................................................................... 3534
6.2 Removing and installing exhaust manifold.................................................................................................................................................................................................................................................................................................................................................................................................................. 3535
6.2.1 Removing and installing exhaust manifold (left-side)................................................................................................................................................................................................................................................................................................................................................................................................ 3535
6.2.2 Removing and installing exhaust manifold (right-side)............................................................................................................................................................................................................................................................................................................................................................................................... 3535
6.2.3 Removing and installing intermediate pipe (left-side)............................................................................................................................................................................................................................................................................................................................................................................................... 3536
6.2.4 Removing and installing intermediate pipe (right-side).............................................................................................................................................................................................................................................................................................................................................................................................. 3538
28 – Glow plug system................................................................................................................................................................................................................................................................................................................................................................................................................................................. 3539
1 Glow plug system................................................................................................................................................................................................................................................................................................................................................................................................................................................ 3539
1.1 Removing and installing glow plug......................................................................................................................................................................................................................................................................................................................................................................................................................... 3539
1.1.1 Removing and installing glow plugs - engine codes CAMA, CAPA, CAMB, CCWA, CCWB, CGKA, CGKB.......................................................................................................................................................................................................................................................................................................................................................... 3539
1.1.2 Removing and installing glow plugs - engine code CCLA............................................................................................................................................................................................................................................................................................................................................................................................... 3540
1.2 Removing and installing engine speed sender -G28-......................................................................................................................................................................................................................................................................................................................................................................................................... 3542
6-cylinder_TDI_engine_(3_0_ltr__4-valve_common_rail_-_generation_II)...................................................................................................................................................................................................................................................................................................................................................................................................... 3543
00 – Technical data................................................................................................................................................................................................................................................................................................................................................................................................................................................... 3551
1 Identification.................................................................................................................................................................................................................................................................................................................................................................................................................................................. 3551
1.1 Engine identification number/engine data.................................................................................................................................................................................................................................................................................................................................................................................................................. 3551
2 Safety precautions.............................................................................................................................................................................................................................................................................................................................................................................................................................................. 3552
2.1 Safety precautions when working on the fuel supply system................................................................................................................................................................................................................................................................................................................................................................................................. 3552
2.2 Working on the reducing agent metering system - vehicles with SCR catalytic converter..................................................................................................................................................................................................................................................................................................................................................................... 3554
2.3 Adapting learnt value after draining reducing agent or renewing components................................................................................................................................................................................................................................................................................................................................................................................ 3555
2.4 Safety precautions when working on vehicles with start/stop system........................................................................................................................................................................................................................................................................................................................................................................................ 3555
2.5 Safety precautions when using testers and measuring instruments during a road test........................................................................................................................................................................................................................................................................................................................................................................ 3555
2.6 Safety precautions when working on the cooling system..................................................................................................................................................................................................................................................................................................................................................................................................... 3556
2.7 Safety precautions when working on the subframe........................................................................................................................................................................................................................................................................................................................................................................................................... 3556
2.8 Safety precautions when working on the exhaust system..................................................................................................................................................................................................................................................................................................................................................................................................... 3556
3 Repair instructions............................................................................................................................................................................................................................................................................................................................................................................................................................................. 3558
3.1 Rules for cleanliness..................................................................................................................................................................................................................................................................................................................................................................................................................................... 3558
3.2 General notes............................................................................................................................................................................................................................................................................................................................................................................................................................................. 3558
3.3 General repair instructions............................................................................................................................................................................................................................................................................................................................................................................................................................... 3559
3.4 Foreign particles in engine............................................................................................................................................................................................................................................................................................................................................................................................................................... 3560
3.5 Contact corrosion......................................................................................................................................................................................................................................................................................................................................................................................................................................... 3560
3.6 Routing and attachment of pipes, hoses and wiring......................................................................................................................................................................................................................................................................................................................................................................................................... 3560
3.7 Installing radiators and condensers....................................................................................................................................................................................................................................................................................................................................................................................................................... 3560
3.8 Checking vacuum system.................................................................................................................................................................................................................................................................................................................................................................................................................................... 3560
10 – Removing and installing engine................................................................................................................................................................................................................................................................................................................................................................................................................................... 3562
1 Removing and installing engine.................................................................................................................................................................................................................................................................................................................................................................................................................................. 3562
1.1 Removing engine........................................................................................................................................................................................................................................................................................................................................................................................................................................... 3562
1.1.1 Removing engine, vehicles with manual gearbox....................................................................................................................................................................................................................................................................................................................................................................................................... 3562
1.1.2 Removing engine, vehicles with multitronic gearbox 0AW.............................................................................................................................................................................................................................................................................................................................................................................................. 3579
1.1.3 Removing engine, vehicles with dual clutch gearbox 0B5.............................................................................................................................................................................................................................................................................................................................................................................................. 3596
1.2 Separating engine and gearbox............................................................................................................................................................................................................................................................................................................................................................................................................................. 3613
1.2.1 Separating engine and gearbox - manual gearbox...................................................................................................................................................................................................................................................................................................................................................................................................... 3613
1.2.2 Separating engine and gearbox, vehicles with multitronic gearbox 0AW................................................................................................................................................................................................................................................................................................................................................................................ 3618
1.2.3 Separating engine and gearbox, vehicles with dual clutch gearbox 0B5................................................................................................................................................................................................................................................................................................................................................................................ 3624
1.3 Securing engine to engine and gearbox support............................................................................................................................................................................................................................................................................................................................................................................................................. 3630
1.4 Installing engine......................................................................................................................................................................................................................................................................................................................................................................................................................................... 3633
2 Assembly mountings.............................................................................................................................................................................................................................................................................................................................................................................................................................................. 3642
2.1 Exploded view - assembly mountings........................................................................................................................................................................................................................................................................................................................................................................................................................ 3642
2.2 Removing and installing engine mountings.................................................................................................................................................................................................................................................................................................................................................................................................................. 3643
3 Engine cover panel.............................................................................................................................................................................................................................................................................................................................................................................................................................................. 3647
3.1 Removing and installing engine cover panel................................................................................................................................................................................................................................................................................................................................................................................................................ 3647
13 – Crankshaft group................................................................................................................................................................................................................................................................................................................................................................................................................................................. 3648
1 Cylinder block (pulley end)..................................................................................................................................................................................................................................................................................................................................................................................................................................... 3648
1.1 Exploded view - poly V-belt drive......................................................................................................................................................................................................................................................................................................................................................................................................................... 3648
1.2 Exploded view - sealing flange (pulley end)............................................................................................................................................................................................................................................................................................................................................................................................................... 3650
1.3 Removing and installing poly V-belt....................................................................................................................................................................................................................................................................................................................................................................................................................... 3655
1.4 Removing and installing tensioner for poly V-belt......................................................................................................................................................................................................................................................................................................................................................................................................... 3657
1.5 Removing and installing vibration damper.................................................................................................................................................................................................................................................................................................................................................................................................................. 3658
1.6 Removing and installing bracket for ancillaries........................................................................................................................................................................................................................................................................................................................................................................................................... 3659
1.7 Renewing crankshaft oil seal (pulley end)................................................................................................................................................................................................................................................................................................................................................................................................................. 3659
1.8 Removing and installing sealing flange (pulley end)....................................................................................................................................................................................................................................................................................................................................................................................................... 3661
2 Cylinder block (gearbox end).................................................................................................................................................................................................................................................................................................................................................................................................................................... 3665
2.1 Exploded view - drive plate............................................................................................................................................................................................................................................................................................................................................................................................................................... 3665
2.2 Removing and installing drive plate....................................................................................................................................................................................................................................................................................................................................................................................................................... 3666
2.3 Removing and installing sender wheel...................................................................................................................................................................................................................................................................................................................................................................................................................... 3667
2.4 Checking sender wheel..................................................................................................................................................................................................................................................................................................................................................................................................................................... 3668
2.5 Renewing crankshaft oil seal (gearbox end)................................................................................................................................................................................................................................................................................................................................................................................................................ 3669
3 Crankshaft...................................................................................................................................................................................................................................................................................................................................................................................................................................................... 3671
3.1 Exploded view - crankshaft................................................................................................................................................................................................................................................................................................................................................................................................................................ 3671
3.2 Crankshaft dimensions..................................................................................................................................................................................................................................................................................................................................................................................................................................... 3673
3.3 Measuring axial clearance of crankshaft................................................................................................................................................................................................................................................................................................................................................................................................................... 3673
3.4 Measuring radial clearance of crankshaft.................................................................................................................................................................................................................................................................................................................................................................................................................. 3674
4 Balance shaft................................................................................................................................................................................................................................................................................................................................................................................................................................................... 3675
4.1 Exploded view - balance shaft............................................................................................................................................................................................................................................................................................................................................................................................................................. 3675
4.2 Renewing roller bearing for balance shaft................................................................................................................................................................................................................................................................................................................................................................................................................. 3675
4.3 Removing and installing balance shaft..................................................................................................................................................................................................................................................................................................................................................................................................................... 3676
5 Pistons and conrods............................................................................................................................................................................................................................................................................................................................................................................................................................................. 3679
5.1 Exploded view - pistons and conrods....................................................................................................................................................................................................................................................................................................................................................................................................................... 3679
5.2 Removing and installing pistons........................................................................................................................................................................................................................................................................................................................................................................................................................... 3681
5.3 Measuring piston projection at TDC........................................................................................................................................................................................................................................................................................................................................................................................................................ 3682
5.4 Checking pistons and cylinder bores....................................................................................................................................................................................................................................................................................................................................................................................................................... 3685
5.5 Checking radial clearance of conrod bearings.............................................................................................................................................................................................................................................................................................................................................................................................................. 3686
15 – Cylinder head, valve gear........................................................................................................................................................................................................................................................................................................................................................................................................................................ 3687
1 Cylinder head................................................................................................................................................................................................................................................................................................................................................................................................................................................... 3687
1.1 Exploded view - cylinder head............................................................................................................................................................................................................................................................................................................................................................................................................................. 3687
1.2 Exploded view - cylinder head cover....................................................................................................................................................................................................................................................................................................................................................................................................................... 3689
1.3 Removing and installing cylinder head..................................................................................................................................................................................................................................................................................................................................................................................................................... 3691
1.4 Removing and installing cylinder head cover............................................................................................................................................................................................................................................................................................................................................................................................................... 3697
1.4.1 Removing and installing cylinder head cover (left-side)............................................................................................................................................................................................................................................................................................................................................................................................. 3697
1.4.2 Removing and installing cylinder head cover (right-side)............................................................................................................................................................................................................................................................................................................................................................................................ 3700
1.5 Removing and installing seals for injectors............................................................................................................................................................................................................................................................................................................................................................................................................... 3702
1.6 Checking compression...................................................................................................................................................................................................................................................................................................................................................................................................................................... 3704
2 Timing chain cover.............................................................................................................................................................................................................................................................................................................................................................................................................................................. 3706
2.1 Exploded view - timing chain cover........................................................................................................................................................................................................................................................................................................................................................................................................................ 3706
2.2 Removing and installing timing chain cover................................................................................................................................................................................................................................................................................................................................................................................................................ 3708
2.2.1 Removing and installing timing chain covers (top)................................................................................................................................................................................................................................................................................................................................................................................................... 3708
2.2.2 Removing and installing timing chain cover (bottom)................................................................................................................................................................................................................................................................................................................................................................................................. 3711
3 Chain drive..................................................................................................................................................................................................................................................................................................................................................................................................................................................... 3714
3.1 Exploded view - camshaft timing chains.................................................................................................................................................................................................................................................................................................................................................................................................................... 3714
3.2 Exploded view - drive chain for oil pump and high-pressure pump........................................................................................................................................................................................................................................................................................................................................................................................... 3716
3.3 Removing and installing camshaft timing chain............................................................................................................................................................................................................................................................................................................................................................................................................. 3717
3.4 Removing camshaft timing chain from camshafts............................................................................................................................................................................................................................................................................................................................................................................................................. 3725
3.5 Removing and installing drive chain for oil pump and high-pressure pump................................................................................................................................................................................................................................................................................................................................................................................... 3734
4 Valve gear...................................................................................................................................................................................................................................................................................................................................................................................................................................................... 3736
4.1 Exploded view - valve gear................................................................................................................................................................................................................................................................................................................................................................................................................................ 3736
4.2 Measuring axial clearance of camshaft..................................................................................................................................................................................................................................................................................................................................................................................................................... 3739
4.3 Measuring radial clearance of camshaft.................................................................................................................................................................................................................................................................................................................................................................................................................... 3740
4.4 Removing and installing camshaft.......................................................................................................................................................................................................................................................................................................................................................................................................................... 3741
4.4.1 Removing camshafts and re-installing used camshafts - cylinder bank 1 (right-side).................................................................................................................................................................................................................................................................................................................................................................. 3741
4.4.2 Removing and renewing camshafts or camshaft bearings - cylinder bank 1 (right-side)................................................................................................................................................................................................................................................................................................................................................................. 3747
4.4.3 Removing camshafts and re-installing used camshafts - cylinder bank 2 (left-side)................................................................................................................................................................................................................................................................................................................................................................... 3753
4.4.4 Removing and renewing camshafts or camshaft bearings - cylinder bank 2 (left-side).................................................................................................................................................................................................................................................................................................................................................................. 3757
4.5 Checking hydraulic compensation elements.................................................................................................................................................................................................................................................................................................................................................................................................................. 3762
4.6 Removing and installing valve stem oil seals.............................................................................................................................................................................................................................................................................................................................................................................................................. 3764
4.6.1 Renewing valve stem oil seals with cylinder head installed.......................................................................................................................................................................................................................................................................................................................................................................................... 3764
4.6.2 Renewing valve stem oil seals with cylinder head removed............................................................................................................................................................................................................................................................................................................................................................................................ 3767
5 Inlet and exhaust valves........................................................................................................................................................................................................................................................................................................................................................................................................................................ 3771
5.1 Machining valve seats..................................................................................................................................................................................................................................................................................................................................................................................................................................... 3771
5.2 Checking valve guides..................................................................................................................................................................................................................................................................................................................................................................................................................................... 3771
5.3 Checking valves........................................................................................................................................................................................................................................................................................................................................................................................................................................... 3772
5.4 Valve dimensions.......................................................................................................................................................................................................................................................................................................................................................................................................................................... 3773
17 – Lubrication...................................................................................................................................................................................................................................................................................................................................................................................................................................................... 3774
1 Sump/oil pump................................................................................................................................................................................................................................................................................................................................................................................................................................................... 3774
1.1 Exploded view - sump/oil pump............................................................................................................................................................................................................................................................................................................................................................................................................................. 3774
1.1.1 Exploded view - sump (bottom section) and oil pump.................................................................................................................................................................................................................................................................................................................................................................................................. 3774
1.1.2 Exploded view - sump (top section).................................................................................................................................................................................................................................................................................................................................................................................................................. 3777
1.2 Engine oil................................................................................................................................................................................................................................................................................................................................................................................................................................................ 3778
1.3 Checking oil level........................................................................................................................................................................................................................................................................................................................................................................................................................................ 3778
1.4 Removing and installing sump (bottom section)............................................................................................................................................................................................................................................................................................................................................................................................................. 3778
1.5 Removing and installing sump (top section)................................................................................................................................................................................................................................................................................................................................................................................................................ 3780
1.6 Removing and installing oil pump.......................................................................................................................................................................................................................................................................................................................................................................................................................... 3782
1.7 Removing and installing oil level and oil temperature sender -G266-....................................................................................................................................................................................................................................................................................................................................................................................... 3783
2 Engine oil cooler............................................................................................................................................................................................................................................................................................................................................................................................................................................... 3784
2.1 Exploded view - engine oil cooler......................................................................................................................................................................................................................................................................................................................................................................................................................... 3784
2.2 Removing and installing engine oil cooler................................................................................................................................................................................................................................................................................................................................................................................................................. 3785
2.3 Removing and installing mounting plate for engine oil cooler/coolant shut-off valve....................................................................................................................................................................................................................................................................................................................................................................... 3786
2.4 Removing and installing temperature regulator for engine oil cooler....................................................................................................................................................................................................................................................................................................................................................................................... 3786
3 Oil filter/oil pressure switches................................................................................................................................................................................................................................................................................................................................................................................................................................ 3788
3.1 Exploded view - oil filter housing/oil pressure switches.................................................................................................................................................................................................................................................................................................................................................................................................. 3788
3.2 Checking oil pressure switch -F22-/oil pressure switch for reduced oil pressure -F378-.................................................................................................................................................................................................................................................................................................................................................................... 3789
3.3 Removing and installing oil pressure switch -F22-/oil pressure switch for reduced oil pressure -F378-..................................................................................................................................................................................................................................................................................................................................................... 3789
3.4 Removing and installing oil temperature sender 2 -G664-................................................................................................................................................................................................................................................................................................................................................................................................... 3791
3.5 Removing and installing valve for oil pressure control -N428-............................................................................................................................................................................................................................................................................................................................................................................................. 3792
3.6 Checking oil pressure..................................................................................................................................................................................................................................................................................................................................................................................................................................... 3792
3.7 Removing and installing oil filter housing................................................................................................................................................................................................................................................................................................................................................................................................................ 3793
19 – Cooling.......................................................................................................................................................................................................................................................................................................................................................................................................................................................... 3795
1 Cooling system/coolant.......................................................................................................................................................................................................................................................................................................................................................................................................................................... 3795
1.1 Connection diagram - coolant hoses........................................................................................................................................................................................................................................................................................................................................................................................................................ 3795
1.1.1 Connection diagram - coolant hoses, vehicles without auxiliary heater............................................................................................................................................................................................................................................................................................................................................................................... 3795
1.1.2 Connection diagram - coolant hoses, vehicles with auxiliary heater.................................................................................................................................................................................................................................................................................................................................................................................. 3797
1.2 Draining and filling cooling system....................................................................................................................................................................................................................................................................................................................................................................................................................... 3799
1.3 Checking cooling system for leaks......................................................................................................................................................................................................................................................................................................................................................................................................................... 3805
2 Coolant pump/thermostat assembly................................................................................................................................................................................................................................................................................................................................................................................................................................ 3808
2.1 Exploded view - coolant pump.............................................................................................................................................................................................................................................................................................................................................................................................................................. 3808
2.2 Exploded view - coolant temperature senders............................................................................................................................................................................................................................................................................................................................................................................................................... 3810
2.3 Exploded view - coolant shut-off valve.................................................................................................................................................................................................................................................................................................................................................................................................................... 3811
2.4 Removing and installing coolant pump...................................................................................................................................................................................................................................................................................................................................................................................................................... 3811
2.5 Removing and installing map-controlled engine cooling system thermostat -F265-............................................................................................................................................................................................................................................................................................................................................................................ 3813
2.6 Removing and installing coolant valves.................................................................................................................................................................................................................................................................................................................................................................................................................... 3813
2.6.1 Removing and installing non-return valve (cylinder bank 1).......................................................................................................................................................................................................................................................................................................................................................................................... 3813
2.6.2 Removing and installing non-return valve (cylinder bank 2).......................................................................................................................................................................................................................................................................................................................................................................................... 3814
2.7 Removing and installing coolant shut-off valve............................................................................................................................................................................................................................................................................................................................................................................................................ 3815
2.8 Removing and installing coolant temperature sender -G62-.................................................................................................................................................................................................................................................................................................................................................................................................. 3816
2.9 Removing and installing temperature sender for engine temperature regulation -G694-....................................................................................................................................................................................................................................................................................................................................................................... 3817
2.10 Removing and installing radiator outlet coolant temperature sender -G83-................................................................................................................................................................................................................................................................................................................................................................................. 3818
3 Coolant pipes................................................................................................................................................................................................................................................................................................................................................................................................................................................... 3820
3.1 Exploded view - coolant pipes............................................................................................................................................................................................................................................................................................................................................................................................................................. 3820
3.2 Removing and installing coolant pipes..................................................................................................................................................................................................................................................................................................................................................................................................................... 3821
3.2.1 Removing and installing coolant pipe (top).......................................................................................................................................................................................................................................................................................................................................................................................................... 3821
3.2.2 Removing and installing coolant pipe (front)........................................................................................................................................................................................................................................................................................................................................................................................................ 3822
3.2.3 Removing and installing coolant pipe (rear left).................................................................................................................................................................................................................................................................................................................................................................................................... 3823
3.2.4 Removing and installing coolant pipe (front left)................................................................................................................................................................................................................................................................................................................................................................................................... 3825
4 Radiator/radiator fans.......................................................................................................................................................................................................................................................................................................................................................................................................................................... 3826
4.1 Exploded view - radiator/radiator fans.................................................................................................................................................................................................................................................................................................................................................................................................................... 3826
4.2 Exploded view - radiator cowl and radiator fans........................................................................................................................................................................................................................................................................................................................................................................................................... 3828
4.3 Removing and installing radiator.......................................................................................................................................................................................................................................................................................................................................................................................................................... 3828
4.4 Removing and installing radiator cowl..................................................................................................................................................................................................................................................................................................................................................................................................................... 3834
4.5 Removing and installing radiator fans..................................................................................................................................................................................................................................................................................................................................................................................................................... 3840
21 – Turbocharging/supercharging...................................................................................................................................................................................................................................................................................................................................................................................................................................... 3841
1 Turbocharger.................................................................................................................................................................................................................................................................................................................................................................................................................................................... 3841
1.1 Exploded view - turbocharger.............................................................................................................................................................................................................................................................................................................................................................................................................................. 3841
1.2 Removing and installing turbocharger...................................................................................................................................................................................................................................................................................................................................................................................................................... 3843
1.3 Removing and installing turbocharger 1 control unit -J724-................................................................................................................................................................................................................................................................................................................................................................................................ 3846
2 Charge air system............................................................................................................................................................................................................................................................................................................................................................................................................................................... 3858
2.1 Exploded view - charge air system......................................................................................................................................................................................................................................................................................................................................................................................................................... 3858
2.2 Removing and installing charge air cooler................................................................................................................................................................................................................................................................................................................................................................................................................. 3860
2.3 Removing and installing charge pressure sender -G31- / intake air temperature sender -G42-................................................................................................................................................................................................................................................................................................................................................................ 3862
2.4 Checking charge air system for leaks...................................................................................................................................................................................................................................................................................................................................................................................................................... 3863
23 – Mixture preparation - injection.................................................................................................................................................................................................................................................................................................................................................................................................................................. 3867
1 Injection system................................................................................................................................................................................................................................................................................................................................................................................................................................................ 3867
1.1 Overview of fitting locations - injection system.......................................................................................................................................................................................................................................................................................................................................................................................................... 3867
1.2 Overview - fuel system.................................................................................................................................................................................................................................................................................................................................................................................................................................... 3876
1.3 Filling and bleeding fuel system.......................................................................................................................................................................................................................................................................................................................................................................................................................... 3878
1.4 Checking fuel system for leaks............................................................................................................................................................................................................................................................................................................................................................................................................................ 3879
2 Vacuum system................................................................................................................................................................................................................................................................................................................................................................................................................................................... 3881
2.1 Connection diagram - vacuum system........................................................................................................................................................................................................................................................................................................................................................................................................................ 3881
2.2 Checking vacuum system.................................................................................................................................................................................................................................................................................................................................................................................................................................... 3881
3 Air cleaner..................................................................................................................................................................................................................................................................................................................................................................................................................................................... 3883
3.1 Exploded view - air cleaner housing....................................................................................................................................................................................................................................................................................................................................................................................................................... 3883
3.2 Removing and installing air filter element................................................................................................................................................................................................................................................................................................................................................................................................................ 3885
3.3 Removing and installing air cleaner housing............................................................................................................................................................................................................................................................................................................................................................................................................... 3887
4 Intake manifold................................................................................................................................................................................................................................................................................................................................................................................................................................................. 3889
4.1 Exploded view - intake manifold........................................................................................................................................................................................................................................................................................................................................................................................................................... 3889
4.2 Removing and installing intake manifold................................................................................................................................................................................................................................................................................................................................................................................................................... 3890
4.3 Removing and installing intake manifold flap motor -V157-................................................................................................................................................................................................................................................................................................................................................................................................. 3895
4.4 Removing and installing throttle valve module -J338-...................................................................................................................................................................................................................................................................................................................................................................................................... 3897
5 Injectors/high-pressure reservoir (rail)........................................................................................................................................................................................................................................................................................................................................................................................................................ 3898
5.1 Exploded view - injectors................................................................................................................................................................................................................................................................................................................................................................................................................................. 3898
5.2 Checking injectors........................................................................................................................................................................................................................................................................................................................................................................................................................................ 3901
5.3 Performing adaption of correction values for injectors.................................................................................................................................................................................................................................................................................................................................................................................................... 3902
5.4 Checking for injectors sticking open...................................................................................................................................................................................................................................................................................................................................................................................................................... 3902
5.5 Checking return flow rate of injectors with engine running................................................................................................................................................................................................................................................................................................................................................................................................ 3904
5.6 Checking return flow rate of injectors at starter cranking speed.......................................................................................................................................................................................................................................................................................................................................................................................... 3907
5.7 Checking restrictor in fuel return line................................................................................................................................................................................................................................................................................................................................................................................................................... 3909
5.8 Removing and installing injectors......................................................................................................................................................................................................................................................................................................................................................................................................................... 3910
5.9 Removing and installing high-pressure pipes............................................................................................................................................................................................................................................................................................................................................................................................................... 3916
5.10 Removing and installing high-pressure reservoir (rail)................................................................................................................................................................................................................................................................................................................................................................................................... 3917
6 High-pressure pump.............................................................................................................................................................................................................................................................................................................................................................................................................................................. 3922
6.1 Exploded view - high-pressure pump........................................................................................................................................................................................................................................................................................................................................................................................................................ 3922
6.2 Removing and installing high-pressure pump................................................................................................................................................................................................................................................................................................................................................................................................................ 3923
7 Senders and sensors............................................................................................................................................................................................................................................................................................................................................................................................................................................. 3929
7.1 Checking fuel pressure regulating valve -N276-............................................................................................................................................................................................................................................................................................................................................................................................................ 3929
7.2 Removing and installing fuel pressure regulating valve -N276-............................................................................................................................................................................................................................................................................................................................................................................................. 3932
7.3 Removing and installing fuel pressure sender -G247-....................................................................................................................................................................................................................................................................................................................................................................................................... 3933
7.4 Removing and installing air mass meter -G70-.............................................................................................................................................................................................................................................................................................................................................................................................................. 3936
7.5 Removing and installing pressure differential sender -G505-............................................................................................................................................................................................................................................................................................................................................................................................... 3937
8 Lambda probe.................................................................................................................................................................................................................................................................................................................................................................................................................................................... 3939
8.1 Exploded view - Lambda probe, exhaust gas temperature senders and pressure sender......................................................................................................................................................................................................................................................................................................................................................................... 3939
8.2 Removing and installing Lambda probe...................................................................................................................................................................................................................................................................................................................................................................................................................... 3940
9 Engine control unit............................................................................................................................................................................................................................................................................................................................................................................................................................................. 3942
9.1 Wiring and component check with isolator box -VAS 6606-................................................................................................................................................................................................................................................................................................................................................................................................... 3942
9.2 Removing and installing engine control unit -J623-........................................................................................................................................................................................................................................................................................................................................................................................................ 3943
26 – Exhaust system................................................................................................................................................................................................................................................................................................................................................................................................................................................... 3945
1 Exhaust pipes/silencers......................................................................................................................................................................................................................................................................................................................................................................................................................................... 3945
1.1 Exploded view - silencers................................................................................................................................................................................................................................................................................................................................................................................................................................. 3945
1.2 Removing and installing front exhaust pipe................................................................................................................................................................................................................................................................................................................................................................................................................ 3949
1.2.1 Removing and installing front exhaust pipe - vehicles with dual clutch gearbox 0B5.................................................................................................................................................................................................................................................................................................................................................................. 3949
1.2.2 Removing and installing front exhaust pipe - vehicles with manual gearbox/multitronic 0AW........................................................................................................................................................................................................................................................................................................................................................... 3950
1.3 Separating exhaust pipes/silencers........................................................................................................................................................................................................................................................................................................................................................................................................................ 3952
1.4 Renewing tailpipes........................................................................................................................................................................................................................................................................................................................................................................................................................................ 3953
1.5 Stress-free alignment of exhaust system................................................................................................................................................................................................................................................................................................................................................................................................................... 3954
1.6 Checking exhaust system for leaks......................................................................................................................................................................................................................................................................................................................................................................................................................... 3955
2 Emission control system......................................................................................................................................................................................................................................................................................................................................................................................................................................... 3956
2.1 Removing and installing particulate filter................................................................................................................................................................................................................................................................................................................................................................................................................ 3956
2.1.1 Removing and installing particulate filter, vehicles with manual gearbox/multitronic gearbox 0AW.................................................................................................................................................................................................................................................................................................................................................... 3956
2.1.2 Removing and installing particulate filter - vehicles with dual clutch gearbox 0B5.................................................................................................................................................................................................................................................................................................................................................................. 3957
3 SCR (selective catalytic reduction) system...................................................................................................................................................................................................................................................................................................................................................................................................................... 3960
3.1 Exploded view - reducing agent tank....................................................................................................................................................................................................................................................................................................................................................................................................................... 3960
3.1.1 Exploded view - active tank for reducing agent with attached components............................................................................................................................................................................................................................................................................................................................................................................. 3960
3.1.2 Exploded view - passive tank for reducing agent with attached components............................................................................................................................................................................................................................................................................................................................................................................ 3962
3.2 Exploded view - pump for reducing agent -V437-............................................................................................................................................................................................................................................................................................................................................................................................................ 3963
3.3 Exploded view - delivery unit for reducing agent.......................................................................................................................................................................................................................................................................................................................................................................................................... 3965
3.3.1 Exploded view - delivery unit for reducing agent, vehicles with external pump for reducing agent.................................................................................................................................................................................................................................................................................................................................................... 3965
3.3.2 Exploded view - delivery unit for reducing agent, vehicles with internal pump for reducing agent.................................................................................................................................................................................................................................................................................................................................................... 3966
3.4 Exploded view - injector for reducing agent -N474-........................................................................................................................................................................................................................................................................................................................................................................................................ 3967
3.5 Exploded view - control unit for reducing agent metering system........................................................................................................................................................................................................................................................................................................................................................................................... 3968
3.6 Removing and installing reducing agent supply line........................................................................................................................................................................................................................................................................................................................................................................................................ 3968
3.7 Removing and installing delivery unit for reducing agent.................................................................................................................................................................................................................................................................................................................................................................................................. 3970
3.7.1 Removing and installing delivery unit for reducing agent, vehicles with external pump for reducing agent............................................................................................................................................................................................................................................................................................................................................ 3970
3.7.2 Removing and installing delivery unit for reducing agent, vehicles with internal pump for reducing agent............................................................................................................................................................................................................................................................................................................................................ 3973
3.8 Removing and installing injector for reducing agent -N474-................................................................................................................................................................................................................................................................................................................................................................................................ 3975
3.9 Draining active tank for reducing agent................................................................................................................................................................................................................................................................................................................................................................................................................... 3976
3.10 Removing and installing active tank for reducing agent................................................................................................................................................................................................................................................................................................................................................................................................... 3978
3.11 Draining passive tank for reducing agent................................................................................................................................................................................................................................................................................................................................................................................................................. 3981
3.12 Removing and installing passive tank for reducing agent.................................................................................................................................................................................................................................................................................................................................................................................................. 3982
3.13 Removing and installing pressure sender for reducing agent metering system -G686-........................................................................................................................................................................................................................................................................................................................................................................ 3985
3.14 Removing and installing pump for reducing agent -V437-................................................................................................................................................................................................................................................................................................................................................................................................... 3986
3.15 Checking control unit for reducing agent metering system -J880-.......................................................................................................................................................................................................................................................................................................................................................................................... 3987
3.16 Removing and installing control unit for reducing agent metering system -J880-........................................................................................................................................................................................................................................................................................................................................................................... 3987
3.17 Removing and installing transfer pump for reducing agent -V436-.......................................................................................................................................................................................................................................................................................................................................................................................... 3989
4 Exhaust gas temperature control................................................................................................................................................................................................................................................................................................................................................................................................................................. 3992
4.1 Exploded view - exhaust gas temperature control........................................................................................................................................................................................................................................................................................................................................................................................................... 3992
4.2 Removing and installing exhaust gas temperature sender.................................................................................................................................................................................................................................................................................................................................................................................................... 3993
4.2.1 Removing and installing exhaust gas temperature sender 1 -G235-..................................................................................................................................................................................................................................................................................................................................................................................... 3993
4.2.2 Removing and installing exhaust gas temperature sender 2 -G448-..................................................................................................................................................................................................................................................................................................................................................................................... 3995
4.2.3 Removing and installing exhaust gas temperature sender 3 -G495-..................................................................................................................................................................................................................................................................................................................................................................................... 3996
4.2.4 Removing and installing exhaust gas temperature sender 4 -G648-..................................................................................................................................................................................................................................................................................................................................................................................... 3998
4.2.5 Removing and installing particulate sensor -G784-................................................................................................................................................................................................................................................................................................................................................................................................... 3999
4.2.6 Removing and installing control unit for NOx sender 2 -J881- with NOx sender 2 -G687-............................................................................................................................................................................................................................................................................................................................................................... 4001
5 Exhaust gas recirculation....................................................................................................................................................................................................................................................................................................................................................................................................................................... 4003
5.1 Exploded view - exhaust gas recirculation system.......................................................................................................................................................................................................................................................................................................................................................................................................... 4003
5.2 Removing and installing exhaust gas recirculation cooler.................................................................................................................................................................................................................................................................................................................................................................................................. 4006
5.3 Removing and installing exhaust gas recirculation control motor -V338-.................................................................................................................................................................................................................................................................................................................................................................................... 4006
5.4 Removing and installing exhaust gas recirculation temperature sensor -G98-................................................................................................................................................................................................................................................................................................................................................................................ 4007
6 Exhaust manifolds............................................................................................................................................................................................................................................................................................................................................................................................................................................... 4009
6.1 Exploded view - exhaust manifold.......................................................................................................................................................................................................................................................................................................................................................................................................................... 4009
6.2 Removing and installing exhaust manifold.................................................................................................................................................................................................................................................................................................................................................................................................................. 4010
6.2.1 Removing and installing exhaust manifold (left-side)................................................................................................................................................................................................................................................................................................................................................................................................ 4010
6.2.2 Removing and installing exhaust manifold (right-side)............................................................................................................................................................................................................................................................................................................................................................................................... 4012
28 – Glow plug system................................................................................................................................................................................................................................................................................................................................................................................................................................................. 4015
1 Glow plug system................................................................................................................................................................................................................................................................................................................................................................................................................................................ 4015
1.1 Exploded view - glow plug system.......................................................................................................................................................................................................................................................................................................................................................................................................................... 4015
1.2 Removing and installing glow plug......................................................................................................................................................................................................................................................................................................................................................................................................................... 4016
1.3 Checking glow plug........................................................................................................................................................................................................................................................................................................................................................................................................................................ 4017
1.4 Removing and installing Hall sender -G40-................................................................................................................................................................................................................................................................................................................................................................................................................. 4018
1.5 Removing and installing engine speed sender -G28-......................................................................................................................................................................................................................................................................................................................................................................................................... 4019
6-speed_manual_gearbox_0B1__front-wheel_drive............................................................................................................................................................................................................................................................................................................................................................................................................................. 4020
00 – Technical data................................................................................................................................................................................................................................................................................................................................................................................................................................................... 4024
1 Identification.................................................................................................................................................................................................................................................................................................................................................................................................................................................. 4024
1.1 Gearbox identification.................................................................................................................................................................................................................................................................................................................................................................................................................................... 4024
2 Technical data.................................................................................................................................................................................................................................................................................................................................................................................................................................................. 4025
2.1 Allocation of gearbox to engine........................................................................................................................................................................................................................................................................................................................................................................................................................... 4025
2.1.1 Allocation of gearbox to engine - Audi A4 2008 ►.................................................................................................................................................................................................................................................................................................................................................................................................... 4025
2.1.2 Allocation of gearbox to engine - Audi A5 Coupé 2008 ►, Audi A5 Sportback 2010 ►.................................................................................................................................................................................................................................................................................................................................................................... 4027
2.1.3 Allocation of gearbox to engine - Audi A5 Cabriolet 2009 ►.......................................................................................................................................................................................................................................................................................................................................................................................... 4028
2.1.4 Allocation of gearbox to engine - Audi Q5 2008 ►.................................................................................................................................................................................................................................................................................................................................................................................................... 4029
2.2 Capacities................................................................................................................................................................................................................................................................................................................................................................................................................................................ 4030
3 Transmission layout............................................................................................................................................................................................................................................................................................................................................................................................................................................. 4031
3.1 Transmission layout - front-wheel drive................................................................................................................................................................................................................................................................................................................................................................................................................... 4031
4 Repair instructions............................................................................................................................................................................................................................................................................................................................................................................................................................................. 4032
4.1 General repair instructions............................................................................................................................................................................................................................................................................................................................................................................................................................... 4032
5 Safety precautions.............................................................................................................................................................................................................................................................................................................................................................................................................................................. 4035
5.1 Safety precautions when working on vehicles with start/stop system........................................................................................................................................................................................................................................................................................................................................................................................ 4035
6 Electrical components........................................................................................................................................................................................................................................................................................................................................................................................................................................... 4036
6.1 Overview of fitting locations - electrical components..................................................................................................................................................................................................................................................................................................................................................................................................... 4036
30 – Clutch........................................................................................................................................................................................................................................................................................................................................................................................................................................................... 4037
1 Clutch mechanism................................................................................................................................................................................................................................................................................................................................................................................................................................................ 4037
1.1 Exploded view - pedal cluster............................................................................................................................................................................................................................................................................................................................................................................................................................. 4037
1.1.1 Exploded view - pedal cluster, LHD vehicles......................................................................................................................................................................................................................................................................................................................................................................................................... 4037
1.1.2 Exploded view - pedal cluster, RHD vehicles......................................................................................................................................................................................................................................................................................................................................................................................................... 4038
1.2 Exploded view - clutch hydraulics......................................................................................................................................................................................................................................................................................................................................................................................................................... 4041
1.3 Exploded view - clutch release mechanism.................................................................................................................................................................................................................................................................................................................................................................................................................. 4042
1.4 Removing and installing over-centre spring................................................................................................................................................................................................................................................................................................................................................................................................................ 4043
1.5 Removing and installing clutch pedal...................................................................................................................................................................................................................................................................................................................................................................................................................... 4045
1.6 Notes on removing and installing clutch master cylinder and slave cylinder................................................................................................................................................................................................................................................................................................................................................................................ 4046
1.7 Checking clutch master cylinder and clutch slave cylinder................................................................................................................................................................................................................................................................................................................................................................................................. 4046
1.8 Removing and installing clutch master cylinder............................................................................................................................................................................................................................................................................................................................................................................................................ 4047
1.9 Removing and installing clutch slave cylinder............................................................................................................................................................................................................................................................................................................................................................................................................. 4051
1.10 Bleeding clutch hydraulics............................................................................................................................................................................................................................................................................................................................................................................................................................... 4053
2 Clutch.......................................................................................................................................................................................................................................................................................................................................................................................................................................................... 4056
2.1 Exploded view - clutch module............................................................................................................................................................................................................................................................................................................................................................................................................................. 4056
2.2 Exploded view - clutch unit............................................................................................................................................................................................................................................................................................................................................................................................................................... 4057
2.3 Tightening sequence - clutch module to drive plate........................................................................................................................................................................................................................................................................................................................................................................................................ 4057
34 – Controls, housing................................................................................................................................................................................................................................................................................................................................................................................................................................................ 4060
1 Selector mechanism.............................................................................................................................................................................................................................................................................................................................................................................................................................................. 4060
1.1 Overview - selector mechanism............................................................................................................................................................................................................................................................................................................................................................................................................................. 4060
1.2 Exploded view - gear knob and cover....................................................................................................................................................................................................................................................................................................................................................................................................................... 4062
1.3 Exploded view - selector mechanism........................................................................................................................................................................................................................................................................................................................................................................................................................ 4063
1.4 Removing and installing gear knob......................................................................................................................................................................................................................................................................................................................................................................................................................... 4065
1.5 Removing and installing noise insulation.................................................................................................................................................................................................................................................................................................................................................................................................................. 4066
1.6 Removing and installing selector mechanism................................................................................................................................................................................................................................................................................................................................................................................................................ 4067
1.6.1 Removing and installing selector mechanism - Audi A4, A5............................................................................................................................................................................................................................................................................................................................................................................................ 4067
1.6.2 Removing and installing selector mechanism - Audi Q5................................................................................................................................................................................................................................................................................................................................................................................................ 4073
1.7 Adjusting selector mechanism.............................................................................................................................................................................................................................................................................................................................................................................................................................. 4076
1.8 Renewing selector shaft oil seal.......................................................................................................................................................................................................................................................................................................................................................................................................................... 4078
1.9 Removing and installing gear detector switch -F208-....................................................................................................................................................................................................................................................................................................................................................................................................... 4081
1.10 Removing and installing gear detection sensor -G604-..................................................................................................................................................................................................................................................................................................................................................................................................... 4084
1.11 Removing and installing gearbox neutral position sender -G701-........................................................................................................................................................................................................................................................................................................................................................................................... 4088
2 Removing and installing gearbox................................................................................................................................................................................................................................................................................................................................................................................................................................. 4090
2.1 Removing gearbox.......................................................................................................................................................................................................................................................................................................................................................................................................................................... 4090
2.1.1 Removing gearbox - Audi A4, A5 with 1.8 ltr. and 2.0 ltr. TFSI engines.............................................................................................................................................................................................................................................................................................................................................................................. 4090
2.1.2 Removing gearbox - Audi A4, A5 with 4-cyl. TDI engine, PR-TH3/TM4................................................................................................................................................................................................................................................................................................................................................................................... 4099
2.1.3 Removing gearbox - Audi A4, A5, Q5 with 4-cyl. TDI engine (EA 288 - generation I), PR-TD1........................................................................................................................................................................................................................................................................................................................................................... 4112
2.1.4 Removing gearbox - Audi Q5 with 4-cyl. TDI engine, PR-TH3/TM4....................................................................................................................................................................................................................................................................................................................................................................................... 4122
2.1.5 Removing gearbox - Audi A4, A5 with 3.0 ltr. TDI engine............................................................................................................................................................................................................................................................................................................................................................................................. 4133
2.2 Installing gearbox........................................................................................................................................................................................................................................................................................................................................................................................................................................ 4142
2.2.1 Installing gearbox - Audi A4, A5 with 1.8 ltr. and 2.0 ltr. TFSI engines............................................................................................................................................................................................................................................................................................................................................................................ 4142
2.2.2 Installing gearbox - Audi A4, A5 with 4-cyl. TDI engine, PR-TH3/TM4................................................................................................................................................................................................................................................................................................................................................................................. 4150
2.2.3 Installing gearbox - Audi A4, A5, Q5 with 4-cyl. TDI engine (EA 288 - generation I), PR-TD1......................................................................................................................................................................................................................................................................................................................................................... 4160
2.2.4 Installing gearbox - Audi Q5 with 4-cyl. TDI engine, PR-TH3/TM4..................................................................................................................................................................................................................................................................................................................................................................................... 4168
2.2.5 Installing gearbox - Audi A4, A5 with 3.0 ltr. TDI engine........................................................................................................................................................................................................................................................................................................................................................................................... 4175
2.3 Tightening torques for gearbox............................................................................................................................................................................................................................................................................................................................................................................................................................ 4183
3 Transporting gearbox............................................................................................................................................................................................................................................................................................................................................................................................................................................ 4188
4 Assembly mountings.............................................................................................................................................................................................................................................................................................................................................................................................................................................. 4189
4.1 Exploded view - assembly mountings........................................................................................................................................................................................................................................................................................................................................................................................................................ 4189
4.2 Removing and installing tunnel cross member............................................................................................................................................................................................................................................................................................................................................................................................................... 4189
4.3 Removing and installing gearbox support with gearbox mounting............................................................................................................................................................................................................................................................................................................................................................................................. 4191
4.4 Removing and installing gearbox mounting.................................................................................................................................................................................................................................................................................................................................................................................................................. 4192
5 Gear oil........................................................................................................................................................................................................................................................................................................................................................................................................................................................ 4193
5.1 Checking gear oil level................................................................................................................................................................................................................................................................................................................................................................................................................................... 4193
6 Dismantling and assembling gearbox.............................................................................................................................................................................................................................................................................................................................................................................................................................. 4194
35 – Gears, shafts.................................................................................................................................................................................................................................................................................................................................................................................................................................................... 4195
1 Dismantling and assembling gears and shafts..................................................................................................................................................................................................................................................................................................................................................................................................................... 4195
39 – Final drive - front differential................................................................................................................................................................................................................................................................................................................................................................................................................................. 4196
1 Oil seals....................................................................................................................................................................................................................................................................................................................................................................................................................................................... 4196
1.1 Overview of fitting locations - oil seals................................................................................................................................................................................................................................................................................................................................................................................................................. 4196
1.2 Renewing oil seal (right-side)............................................................................................................................................................................................................................................................................................................................................................................................................................ 4197
1.2.1 Renewing oil seal (right-side) - Audi A4, A5........................................................................................................................................................................................................................................................................................................................................................................................................ 4197
1.2.2 Renewing oil seal (right-side) - Audi Q5............................................................................................................................................................................................................................................................................................................................................................................................................ 4201
2 Front differential.............................................................................................................................................................................................................................................................................................................................................................................................................................................. 4206
6-speed_manual_gearbox_0B2__four-wheel_drive.............................................................................................................................................................................................................................................................................................................................................................................................................................. 4207
00 – Technical data................................................................................................................................................................................................................................................................................................................................................................................................................................................... 4211
1 Identification.................................................................................................................................................................................................................................................................................................................................................................................................................................................. 4211
1.1 Gearbox identification.................................................................................................................................................................................................................................................................................................................................................................................................................................... 4211
1.2 Identification of final drive............................................................................................................................................................................................................................................................................................................................................................................................................................. 4212
1.2.1 Identification of final drive - rear final drive 0BC................................................................................................................................................................................................................................................................................................................................................................................................ 4212
1.2.2 Identification of final drive - rear final drive 0BD................................................................................................................................................................................................................................................................................................................................................................................................ 4213
2 Technical data.................................................................................................................................................................................................................................................................................................................................................................................................................................................. 4215
2.1 Allocation of gearbox to engine........................................................................................................................................................................................................................................................................................................................................................................................................................... 4215
2.1.1 Allocation of gearbox to engine - Audi A4 2008 ►.................................................................................................................................................................................................................................................................................................................................................................................................... 4215
2.1.2 Allocation of gearbox to engine - Audi A4 allroad 2008 ►............................................................................................................................................................................................................................................................................................................................................................................................ 4217
2.1.3 Allocation of gearbox to engine, Audi A5 Coupé 2008 ►............................................................................................................................................................................................................................................................................................................................................................................................... 4218
2.1.4 Allocation of gearbox to engine - Audi A5 Sportback 2010 ►.......................................................................................................................................................................................................................................................................................................................................................................................... 4219
2.1.5 Allocation of gearbox to engine - Audi A5 Cabriolet 2009 ►.......................................................................................................................................................................................................................................................................................................................................................................................... 4220
2.1.6 Allocation of gearbox to engine - Audi Q5 2008 ►.................................................................................................................................................................................................................................................................................................................................................................................................... 4221
2.2 Capacities................................................................................................................................................................................................................................................................................................................................................................................................................................................ 4222
3 Repair instructions............................................................................................................................................................................................................................................................................................................................................................................................................................................. 4223
3.1 General repair instructions............................................................................................................................................................................................................................................................................................................................................................................................................................... 4223
4 Safety precautions.............................................................................................................................................................................................................................................................................................................................................................................................................................................. 4226
4.1 Safety precautions when working on vehicles with start/stop system........................................................................................................................................................................................................................................................................................................................................................................................ 4226
5 Electrical components........................................................................................................................................................................................................................................................................................................................................................................................................................................... 4227
5.1 Overview of fitting locations - electrical components..................................................................................................................................................................................................................................................................................................................................................................................................... 4227
30 – Clutch........................................................................................................................................................................................................................................................................................................................................................................................................................................................... 4228
1 Clutch mechanism................................................................................................................................................................................................................................................................................................................................................................................................................................................ 4228
1.1 Exploded view - pedal cluster............................................................................................................................................................................................................................................................................................................................................................................................................................. 4228
1.1.1 Exploded view - pedal cluster, LHD vehicles......................................................................................................................................................................................................................................................................................................................................................................................................... 4228
1.1.2 Exploded view - pedal cluster, RHD vehicles......................................................................................................................................................................................................................................................................................................................................................................................................... 4230
1.2 Exploded view - clutch hydraulics......................................................................................................................................................................................................................................................................................................................................................................................................................... 4232
1.3 Exploded view - clutch release mechanism.................................................................................................................................................................................................................................................................................................................................................................................................................. 4233
1.4 Removing and installing over-centre spring................................................................................................................................................................................................................................................................................................................................................................................................................ 4234
1.5 Removing and installing clutch pedal...................................................................................................................................................................................................................................................................................................................................................................................................................... 4236
1.6 Notes on removing and installing clutch master cylinder and slave cylinder................................................................................................................................................................................................................................................................................................................................................................................ 4237
1.7 Checking clutch master cylinder and clutch slave cylinder................................................................................................................................................................................................................................................................................................................................................................................................. 4237
1.8 Removing and installing clutch master cylinder............................................................................................................................................................................................................................................................................................................................................................................................................ 4238
1.9 Removing and installing clutch slave cylinder............................................................................................................................................................................................................................................................................................................................................................................................................. 4242
1.10 Bleeding clutch hydraulics............................................................................................................................................................................................................................................................................................................................................................................................................................... 4244
2 Clutch.......................................................................................................................................................................................................................................................................................................................................................................................................................................................... 4247
2.1 Exploded view - clutch module............................................................................................................................................................................................................................................................................................................................................................................................................................. 4247
2.2 Exploded view - clutch unit............................................................................................................................................................................................................................................................................................................................................................................................................................... 4248
2.3 Tightening sequence - clutch module to drive plate........................................................................................................................................................................................................................................................................................................................................................................................................ 4248
34 – Controls, housing................................................................................................................................................................................................................................................................................................................................................................................................................................................ 4251
1 Selector mechanism.............................................................................................................................................................................................................................................................................................................................................................................................................................................. 4251
1.1 Overview - selector mechanism............................................................................................................................................................................................................................................................................................................................................................................................................................. 4251
1.2 Exploded view - gear knob and cover....................................................................................................................................................................................................................................................................................................................................................................................................................... 4253
1.3 Exploded view - selector mechanism........................................................................................................................................................................................................................................................................................................................................................................................................................ 4254
1.4 Removing and installing gear knob......................................................................................................................................................................................................................................................................................................................................................................................................................... 4256
1.5 Removing and installing noise insulation.................................................................................................................................................................................................................................................................................................................................................................................................................. 4257
1.6 Removing and installing selector mechanism................................................................................................................................................................................................................................................................................................................................................................................................................ 4258
1.6.1 Removing and installing selector mechanism - Audi A4, A5............................................................................................................................................................................................................................................................................................................................................................................................ 4258
1.6.2 Removing and installing selector mechanism - Audi Q5................................................................................................................................................................................................................................................................................................................................................................................................ 4265
1.7 Adjusting selector mechanism.............................................................................................................................................................................................................................................................................................................................................................................................................................. 4269
1.8 Renewing selector shaft oil seal.......................................................................................................................................................................................................................................................................................................................................................................................................................... 4272
1.9 Removing and installing gear detector switch -F208-....................................................................................................................................................................................................................................................................................................................................................................................................... 4275
1.10 Removing and installing gear detection sensor -G604-..................................................................................................................................................................................................................................................................................................................................................................................................... 4279
1.11 Removing and installing gearbox neutral position sender -G701-........................................................................................................................................................................................................................................................................................................................................................................................... 4283
2 Removing and installing gearbox................................................................................................................................................................................................................................................................................................................................................................................................................................. 4286
2.1 Removing gearbox.......................................................................................................................................................................................................................................................................................................................................................................................................................................... 4286
2.1.1 Removing gearbox - Audi A4, A5 with 1.8 ltr. and 2.0 ltr. TFSI engines.............................................................................................................................................................................................................................................................................................................................................................................. 4286
2.1.2 Removing gearbox - Audi A4, A5 with 3.2 ltr. FSI engine............................................................................................................................................................................................................................................................................................................................................................................................. 4297
2.1.3 Removing gearbox - Audi A4, A5 with 4-cyl. TDI engine, PR-TH3/TM4................................................................................................................................................................................................................................................................................................................................................................................... 4306
2.1.4 Removing gearbox - Audi A4, A5, Q5 with 4-cyl. TDI engine (EA 288 - generation I), PR-TD1........................................................................................................................................................................................................................................................................................................................................................... 4321
2.1.5 Removing gearbox - Audi Q5 with 4-cyl. TDI engine, PR-TH3/TM4....................................................................................................................................................................................................................................................................................................................................................................................... 4331
2.1.6 Removing gearbox - Audi Q5 with 2.0 ltr. TFSI engine................................................................................................................................................................................................................................................................................................................................................................................................ 4344
2.2 Installing gearbox........................................................................................................................................................................................................................................................................................................................................................................................................................................ 4356
2.2.1 Installing gearbox - Audi A4, A5 with 1.8 ltr. and 2.0 ltr. TFSI engines............................................................................................................................................................................................................................................................................................................................................................................ 4356
2.2.2 Installing gearbox - Audi A4, A5 with 3.2 ltr. FSI engine........................................................................................................................................................................................................................................................................................................................................................................................... 4364
2.2.3 Installing gearbox - Audi A4, A5 with 4-cyl. TDI engine, PR-TH3/TM4................................................................................................................................................................................................................................................................................................................................................................................. 4372
2.2.4 Installing gearbox - Audi A4, A5, Q5 with 4-cyl. TDI engine (EA 288 - generation I), PR-TD1......................................................................................................................................................................................................................................................................................................................................................... 4381
2.2.5 Installing gearbox - Audi Q5 with 2.0 ltr. TFSI engine and 4-cyl. TDI engine, PR-TH3/TM4............................................................................................................................................................................................................................................................................................................................................................ 4389
2.3 Tightening torques for gearbox............................................................................................................................................................................................................................................................................................................................................................................................................................ 4398
2.3.1 Tightening torques for gearbox - Audi A4, Audi A5................................................................................................................................................................................................................................................................................................................................................................................................... 4398
2.3.2 Tightening torques for gearbox - Audi Q5............................................................................................................................................................................................................................................................................................................................................................................................................ 4401
3 Transporting gearbox............................................................................................................................................................................................................................................................................................................................................................................................................................................ 4404
4 Assembly mountings.............................................................................................................................................................................................................................................................................................................................................................................................................................................. 4405
4.1 Exploded view - assembly mountings........................................................................................................................................................................................................................................................................................................................................................................................................................ 4405
4.2 Removing and installing tunnel cross member............................................................................................................................................................................................................................................................................................................................................................................................................... 4405
4.3 Removing and installing gearbox support with gearbox mounting............................................................................................................................................................................................................................................................................................................................................................................................. 4407
4.4 Removing and installing gearbox mounting.................................................................................................................................................................................................................................................................................................................................................................................................................. 4408
5 Gear oil........................................................................................................................................................................................................................................................................................................................................................................................................................................................ 4409
5.1 Checking gear oil level................................................................................................................................................................................................................................................................................................................................................................................................................................... 4409
6 Dismantling and assembling gearbox.............................................................................................................................................................................................................................................................................................................................................................................................................................. 4410
35 – Gears, shafts.................................................................................................................................................................................................................................................................................................................................................................................................................................................... 4411
1 Dismantling and assembling gears and shafts..................................................................................................................................................................................................................................................................................................................................................................................................................... 4411
39 – Final drive - front differential................................................................................................................................................................................................................................................................................................................................................................................................................................. 4412
1 Oil seals....................................................................................................................................................................................................................................................................................................................................................................................................................................................... 4412
1.1 Overview of fitting locations - oil seals................................................................................................................................................................................................................................................................................................................................................................................................................. 4412
1.2 Renewing oil seal (right-side)............................................................................................................................................................................................................................................................................................................................................................................................................................ 4413
2 Front differential.............................................................................................................................................................................................................................................................................................................................................................................................................................................. 4418
3 Centre differential............................................................................................................................................................................................................................................................................................................................................................................................................................................. 4419
3.1 Exploded view - centre differential housing............................................................................................................................................................................................................................................................................................................................................................................................................... 4419
3.1.1 Exploded view - centre differential housing with flange shaft (bolted propshaft).................................................................................................................................................................................................................................................................................................................................................................... 4419
3.1.2 Exploded view - centre differential housing with rear splined shaft (propshaft with splines on gearbox end)......................................................................................................................................................................................................................................................................................................................................... 4420
3.2 Removing and installing centre differential housing....................................................................................................................................................................................................................................................................................................................................................................................................... 4422
3.2.1 Removing and installing centre differential housing - bolted propshaft.............................................................................................................................................................................................................................................................................................................................................................................. 4422
3.2.2 Removing and installing centre differential housing - propshaft with splines........................................................................................................................................................................................................................................................................................................................................................................ 4428
3.3 Renewing oil seal for rear splined shaft.................................................................................................................................................................................................................................................................................................................................................................................................................. 4434
3.3.1 Renewing oil seal for rear splined shaft - rear splined shaft without vibration damper.............................................................................................................................................................................................................................................................................................................................................................. 4434
3.3.2 Renewing oil seal for rear splined shaft - rear splined shaft with vibration damper................................................................................................................................................................................................................................................................................................................................................................. 4436
3.4 Renewing oil seal for flange shaft (rear)................................................................................................................................................................................................................................................................................................................................................................................................................. 4436
6-speed_manual_gearbox_0B3__front-wheel_drive............................................................................................................................................................................................................................................................................................................................................................................................................................. 4437
00 – Technical data................................................................................................................................................................................................................................................................................................................................................................................................................................................... 4441
1 Identification.................................................................................................................................................................................................................................................................................................................................................................................................................................................. 4441
1.1 Gearbox identification.................................................................................................................................................................................................................................................................................................................................................................................................................................... 4441
2 Technical data.................................................................................................................................................................................................................................................................................................................................................................................................................................................. 4442
2.1 Allocation of gearbox to engine........................................................................................................................................................................................................................................................................................................................................................................................................................... 4442
2.2 Capacities................................................................................................................................................................................................................................................................................................................................................................................................................................................ 4442
3 Transmission layout............................................................................................................................................................................................................................................................................................................................................................................................................................................. 4443
3.1 Transmission layout - front-wheel drive................................................................................................................................................................................................................................................................................................................................................................................................................... 4443
4 Repair instructions............................................................................................................................................................................................................................................................................................................................................................................................................................................. 4444
4.1 General repair instructions............................................................................................................................................................................................................................................................................................................................................................................................................................... 4444
5 Electrical components........................................................................................................................................................................................................................................................................................................................................................................................................................................... 4448
30 – Clutch........................................................................................................................................................................................................................................................................................................................................................................................................................................................... 4449
1 Clutch mechanism................................................................................................................................................................................................................................................................................................................................................................................................................................................ 4449
1.1 Exploded view - pedal cluster............................................................................................................................................................................................................................................................................................................................................................................................................................. 4449
1.1.1 Exploded view - pedal cluster, LHD vehicles......................................................................................................................................................................................................................................................................................................................................................................................................... 4449
1.1.2 Exploded view - pedal cluster, RHD vehicles......................................................................................................................................................................................................................................................................................................................................................................................................... 4450
1.2 Exploded view - clutch hydraulics......................................................................................................................................................................................................................................................................................................................................................................................................................... 4453
1.3 Exploded view - clutch release mechanism.................................................................................................................................................................................................................................................................................................................................................................................................................. 4454
1.4 Removing and installing clutch pedal...................................................................................................................................................................................................................................................................................................................................................................................................................... 4455
1.5 Removing and installing over-centre spring................................................................................................................................................................................................................................................................................................................................................................................................................ 4456
1.6 Notes on removing and installing clutch master cylinder and slave cylinder................................................................................................................................................................................................................................................................................................................................................................................ 4458
1.7 Checking clutch master cylinder and clutch slave cylinder................................................................................................................................................................................................................................................................................................................................................................................................. 4458
1.8 Removing and installing clutch master cylinder............................................................................................................................................................................................................................................................................................................................................................................................................ 4459
1.9 Removing and installing clutch slave cylinder............................................................................................................................................................................................................................................................................................................................................................................................................. 4464
1.10 Bleeding clutch hydraulics............................................................................................................................................................................................................................................................................................................................................................................................................................... 4466
2 Clutch.......................................................................................................................................................................................................................................................................................................................................................................................................................................................... 4469
2.1 Exploded view - clutch module............................................................................................................................................................................................................................................................................................................................................................................................................................. 4469
2.2 Exploded view - clutch unit............................................................................................................................................................................................................................................................................................................................................................................................................................... 4470
2.3 Tightening sequence - clutch module to drive plate........................................................................................................................................................................................................................................................................................................................................................................................................ 4470
34 – Controls, housing................................................................................................................................................................................................................................................................................................................................................................................................................................................ 4473
1 Selector mechanism.............................................................................................................................................................................................................................................................................................................................................................................................................................................. 4473
1.1 Overview - selector mechanism............................................................................................................................................................................................................................................................................................................................................................................................................................. 4473
1.2 Exploded view - gear knob and cover....................................................................................................................................................................................................................................................................................................................................................................................................................... 4474
1.3 Exploded view - selector mechanism........................................................................................................................................................................................................................................................................................................................................................................................................................ 4475
1.4 Removing and installing gear knob......................................................................................................................................................................................................................................................................................................................................................................................................................... 4477
1.5 Removing and installing noise insulation.................................................................................................................................................................................................................................................................................................................................................................................................................. 4478
1.6 Removing and installing selector mechanism................................................................................................................................................................................................................................................................................................................................................................................................................ 4479
1.7 Adjusting selector mechanism.............................................................................................................................................................................................................................................................................................................................................................................................................................. 4483
1.8 Renewing selector shaft oil seal.......................................................................................................................................................................................................................................................................................................................................................................................................................... 4486
1.9 Removing and installing gear detector switch -F208-....................................................................................................................................................................................................................................................................................................................................................................................................... 4489
2 Removing and installing gearbox................................................................................................................................................................................................................................................................................................................................................................................................................................. 4492
2.1 Removing gearbox.......................................................................................................................................................................................................................................................................................................................................................................................................................................... 4492
2.2 Installing gearbox........................................................................................................................................................................................................................................................................................................................................................................................................................................ 4499
2.3 Tightening torques for gearbox............................................................................................................................................................................................................................................................................................................................................................................................................................ 4507
3 Transporting gearbox............................................................................................................................................................................................................................................................................................................................................................................................................................................ 4509
4 Assembly mountings.............................................................................................................................................................................................................................................................................................................................................................................................................................................. 4510
4.1 Exploded view - assembly mountings........................................................................................................................................................................................................................................................................................................................................................................................................................ 4510
4.2 Removing and installing tunnel cross member............................................................................................................................................................................................................................................................................................................................................................................................................... 4510
4.3 Removing and installing gearbox support with gearbox mounting............................................................................................................................................................................................................................................................................................................................................................................................. 4512
4.4 Removing and installing gearbox mounting.................................................................................................................................................................................................................................................................................................................................................................................................................. 4513
5 Gear oil........................................................................................................................................................................................................................................................................................................................................................................................................................................................ 4514
5.1 Checking gear oil level................................................................................................................................................................................................................................................................................................................................................................................................................................... 4514
6 Dismantling and assembling gearbox.............................................................................................................................................................................................................................................................................................................................................................................................................................. 4515
35 – Gears, shafts.................................................................................................................................................................................................................................................................................................................................................................................................................................................... 4516
1 Dismantling and assembling gears and shafts..................................................................................................................................................................................................................................................................................................................................................................................................................... 4516
39 – Final drive - front differential................................................................................................................................................................................................................................................................................................................................................................................................................................. 4517
1 Oil seals....................................................................................................................................................................................................................................................................................................................................................................................................................................................... 4517
1.1 Overview of fitting locations - oil seals................................................................................................................................................................................................................................................................................................................................................................................................................. 4517
1.2 Renewing oil seal (right-side)............................................................................................................................................................................................................................................................................................................................................................................................................................ 4518
2 Final drive..................................................................................................................................................................................................................................................................................................................................................................................................................................................... 4522
2.1 Renewing cover for final drive............................................................................................................................................................................................................................................................................................................................................................................................................................ 4522
6-speed_manual_gearbox_0B4__four-wheel_drive.............................................................................................................................................................................................................................................................................................................................................................................................................................. 4528
00 – Technical data................................................................................................................................................................................................................................................................................................................................................................................................................................................... 4532
1 Identification.................................................................................................................................................................................................................................................................................................................................................................................................................................................. 4532
1.1 Gearbox identification.................................................................................................................................................................................................................................................................................................................................................................................................................................... 4532
1.2 Identification of final drive............................................................................................................................................................................................................................................................................................................................................................................................................................. 4532
1.2.1 Identification of final drive - rear final drive 0BC................................................................................................................................................................................................................................................................................................................................................................................................ 4532
1.2.2 Identification of final drive - rear final drive 0BF and 0BE (sport differential)................................................................................................................................................................................................................................................................................................................................................................... 4534
2 Technical data.................................................................................................................................................................................................................................................................................................................................................................................................................................................. 4535
2.1 Allocation of gearbox to engine........................................................................................................................................................................................................................................................................................................................................................................................................................... 4535
2.1.1 Allocation of gearbox to engine - Audi A4 2008 ►.................................................................................................................................................................................................................................................................................................................................................................................................... 4535
2.1.2 Allocation of gearbox to engine, Audi A5 Coupé 2008 ►............................................................................................................................................................................................................................................................................................................................................................................................... 4537
2.1.3 Allocation of gearbox to engine - Audi A5 Sportback 2008 ►.......................................................................................................................................................................................................................................................................................................................................................................................... 4538
2.2 Capacities................................................................................................................................................................................................................................................................................................................................................................................................................................................ 4539
3 Transmission layout............................................................................................................................................................................................................................................................................................................................................................................................................................................. 4540
3.1 Transmission layout - four-wheel drive.................................................................................................................................................................................................................................................................................................................................................................................................................... 4540
4 Repair instructions............................................................................................................................................................................................................................................................................................................................................................................................................................................. 4541
4.1 General repair instructions............................................................................................................................................................................................................................................................................................................................................................................................................................... 4541
5 Electrical components........................................................................................................................................................................................................................................................................................................................................................................................................................................... 4545
5.1 Overview of fitting locations - electrical components..................................................................................................................................................................................................................................................................................................................................................................................................... 4545
30 – Clutch........................................................................................................................................................................................................................................................................................................................................................................................................................................................... 4546
1 Clutch mechanism................................................................................................................................................................................................................................................................................................................................................................................................................................................ 4546
1.1 Exploded view - pedal cluster............................................................................................................................................................................................................................................................................................................................................................................................................................. 4546
1.1.1 Exploded view - pedal cluster, LHD vehicles......................................................................................................................................................................................................................................................................................................................................................................................................... 4546
1.1.2 Exploded view - pedal cluster, RHD vehicles......................................................................................................................................................................................................................................................................................................................................................................................................... 4547
1.2 Exploded view - clutch hydraulics......................................................................................................................................................................................................................................................................................................................................................................................................................... 4550
1.3 Exploded view - clutch release mechanism.................................................................................................................................................................................................................................................................................................................................................................................................................. 4551
1.4 Removing and installing over-centre spring................................................................................................................................................................................................................................................................................................................................................................................................................ 4551
1.5 Removing and installing clutch pedal...................................................................................................................................................................................................................................................................................................................................................................................................................... 4554
1.6 Notes on removing and installing clutch master cylinder and slave cylinder................................................................................................................................................................................................................................................................................................................................................................................ 4555
1.7 Checking clutch master cylinder and clutch slave cylinder................................................................................................................................................................................................................................................................................................................................................................................................. 4555
1.8 Removing and installing clutch master cylinder............................................................................................................................................................................................................................................................................................................................................................................................................ 4556
1.9 Removing and installing clutch slave cylinder............................................................................................................................................................................................................................................................................................................................................................................................................. 4560
1.10 Bleeding clutch hydraulics............................................................................................................................................................................................................................................................................................................................................................................................................................... 4562
2 Clutch.......................................................................................................................................................................................................................................................................................................................................................................................................................................................... 4564
2.1 Exploded view - clutch module............................................................................................................................................................................................................................................................................................................................................................................................................................. 4564
2.2 Exploded view - clutch unit............................................................................................................................................................................................................................................................................................................................................................................................................................... 4565
2.3 Tightening sequence - clutch module to drive plate........................................................................................................................................................................................................................................................................................................................................................................................................ 4565
34 – Controls, housing................................................................................................................................................................................................................................................................................................................................................................................................................................................ 4568
1 Selector mechanism.............................................................................................................................................................................................................................................................................................................................................................................................................................................. 4568
1.1 Installation position - selector mechanism................................................................................................................................................................................................................................................................................................................................................................................................................ 4568
1.2 Exploded view - gear knob and cover....................................................................................................................................................................................................................................................................................................................................................................................................................... 4569
1.3 Exploded view - selector mechanism........................................................................................................................................................................................................................................................................................................................................................................................................................ 4570
1.4 Removing and installing gear knob......................................................................................................................................................................................................................................................................................................................................................................................................................... 4572
1.5 Removing and installing noise insulation.................................................................................................................................................................................................................................................................................................................................................................................................................. 4573
1.6 Removing and installing selector mechanism................................................................................................................................................................................................................................................................................................................................................................................................................ 4574
1.7 Adjusting selector mechanism.............................................................................................................................................................................................................................................................................................................................................................................................................................. 4579
1.8 Renewing selector shaft oil seal.......................................................................................................................................................................................................................................................................................................................................................................................................................... 4582
1.9 Removing and installing gear detector switch -F208-....................................................................................................................................................................................................................................................................................................................................................................................................... 4585
1.9.1 Removing and installing gear detection sensor -G604-................................................................................................................................................................................................................................................................................................................................................................................................ 4588
2 Removing and installing gearbox................................................................................................................................................................................................................................................................................................................................................................................................................................. 4592
2.1 Removing gearbox.......................................................................................................................................................................................................................................................................................................................................................................................................................................... 4592
2.1.1 Removing gearbox - vehicles with 3.0 ltr. TFSI engine............................................................................................................................................................................................................................................................................................................................................................................................... 4592
2.1.2 Removing gearbox - vehicles with 4.2 ltr. FSI engine................................................................................................................................................................................................................................................................................................................................................................................................ 4604
2.1.3 Removing gearbox - vehicles with 3.0 ltr. TDI engine................................................................................................................................................................................................................................................................................................................................................................................................ 4616
2.2 Installing gearbox........................................................................................................................................................................................................................................................................................................................................................................................................................................ 4626
2.2.1 Installing gearbox - vehicles with 3.0 ltr. TFSI engine............................................................................................................................................................................................................................................................................................................................................................................................. 4626
2.2.2 Installing gearbox - vehicles with 4.2 ltr. FSI engine.............................................................................................................................................................................................................................................................................................................................................................................................. 4634
2.2.3 Installing gearbox - vehicles with 3.0 ltr. TDI engine.............................................................................................................................................................................................................................................................................................................................................................................................. 4641
2.3 Tightening torques for gearbox............................................................................................................................................................................................................................................................................................................................................................................................................................ 4648
3 Transporting gearbox............................................................................................................................................................................................................................................................................................................................................................................................................................................ 4652
4 Assembly mountings.............................................................................................................................................................................................................................................................................................................................................................................................................................................. 4653
4.1 Exploded view - assembly mountings........................................................................................................................................................................................................................................................................................................................................................................................................................ 4653
4.2 Removing and installing tunnel cross member............................................................................................................................................................................................................................................................................................................................................................................................................... 4653
4.3 Removing and installing gearbox support with gearbox mounting............................................................................................................................................................................................................................................................................................................................................................................................. 4655
4.4 Removing and installing gearbox mounting.................................................................................................................................................................................................................................................................................................................................................................................................................. 4656
5 Dismantling and assembling gearbox.............................................................................................................................................................................................................................................................................................................................................................................................................................. 4657
6 Gear oil........................................................................................................................................................................................................................................................................................................................................................................................................................................................ 4658
6.1 Checking gear oil level................................................................................................................................................................................................................................................................................................................................................................................................................................... 4658
35 – Gears, shafts.................................................................................................................................................................................................................................................................................................................................................................................................................................................... 4659
1 Dismantling and assembling gears and shafts..................................................................................................................................................................................................................................................................................................................................................................................................................... 4659
39 – Final drive - front differential................................................................................................................................................................................................................................................................................................................................................................................................................................. 4660
1 Oil seals....................................................................................................................................................................................................................................................................................................................................................................................................................................................... 4660
1.1 Overview of fitting locations - oil seals................................................................................................................................................................................................................................................................................................................................................................................................................. 4660
1.2 Renewing oil seal (right-side)............................................................................................................................................................................................................................................................................................................................................................................................................................ 4661
2 Final drive..................................................................................................................................................................................................................................................................................................................................................................................................................................................... 4665
2.1 Renewing cover for final drive............................................................................................................................................................................................................................................................................................................................................................................................................................ 4665
3 Front differential.............................................................................................................................................................................................................................................................................................................................................................................................................................................. 4671
4 Centre differential............................................................................................................................................................................................................................................................................................................................................................................................................................................. 4672
4.1 Exploded view - centre differential housing............................................................................................................................................................................................................................................................................................................................................................................................................... 4672
4.2 Removing and installing centre differential housing....................................................................................................................................................................................................................................................................................................................................................................................................... 4673
4.3 Renewing oil seal for rear splined shaft.................................................................................................................................................................................................................................................................................................................................................................................................................. 4678
4.3.1 Renewing oil seal for rear splined shaft - rear splined shaft without vibration damper.............................................................................................................................................................................................................................................................................................................................................................. 4678
4.3.2 Renewing oil seal for rear splined shaft - rear splined shaft with vibration damper................................................................................................................................................................................................................................................................................................................................................................. 4680
4.4 Renewing oil seal for flange shaft (rear)................................................................................................................................................................................................................................................................................................................................................................................................................. 4683
7-speed_dual_clutch_gearbox_0B5_(S_tronic)................................................................................................................................................................................................................................................................................................................................................................................................................................ 4687
00 – Technical data................................................................................................................................................................................................................................................................................................................................................................................................................................................... 4691
1 Identification.................................................................................................................................................................................................................................................................................................................................................................................................................................................. 4691
1.1 Gearbox identification.................................................................................................................................................................................................................................................................................................................................................................................................................................... 4691
2 Safety precautions.............................................................................................................................................................................................................................................................................................................................................................................................................................................. 4692
2.1 Safety precautions when working on vehicle................................................................................................................................................................................................................................................................................................................................................................................................................ 4692
2.2 Safety precautions when working on vehicles with start/stop system........................................................................................................................................................................................................................................................................................................................................................................................ 4693
2.3 Safety precautions when using testers and measuring instruments during a road test........................................................................................................................................................................................................................................................................................................................................................................ 4693
2.4 Notes on tow-starting and towing.......................................................................................................................................................................................................................................................................................................................................................................................................................... 4693
3 Repair instructions............................................................................................................................................................................................................................................................................................................................................................................................................................................. 4694
3.1 Rules for cleanliness..................................................................................................................................................................................................................................................................................................................................................................................................................................... 4694
3.2 General notes............................................................................................................................................................................................................................................................................................................................................................................................................................................. 4694
3.3 General repair instructions............................................................................................................................................................................................................................................................................................................................................................................................................................... 4695
3.4 Contact corrosion......................................................................................................................................................................................................................................................................................................................................................................................................................................... 4697
3.5 Safety functions of gearbox control unit.................................................................................................................................................................................................................................................................................................................................................................................................................. 4697
4 Technical data.................................................................................................................................................................................................................................................................................................................................................................................................................................................. 4698
4.1 Allocation of gearbox to engine........................................................................................................................................................................................................................................................................................................................................................................................................................... 4698
4.2 Capacities................................................................................................................................................................................................................................................................................................................................................................................................................................................ 4701
4.2.1 ATF capacity........................................................................................................................................................................................................................................................................................................................................................................................................................................ 4701
4.2.2 Gear oil (MTF) capacity............................................................................................................................................................................................................................................................................................................................................................................................................................. 4702
30 – Clutch........................................................................................................................................................................................................................................................................................................................................................................................................................................................... 4704
1 Clutch.......................................................................................................................................................................................................................................................................................................................................................................................................................................................... 4704
1.1 Exploded view - flywheel and dual clutch.................................................................................................................................................................................................................................................................................................................................................................................................................. 4704
1.2 Removing and installing flywheel.......................................................................................................................................................................................................................................................................................................................................................................................................................... 4705
1.3 Removing dual clutch...................................................................................................................................................................................................................................................................................................................................................................................................................................... 4705
1.4 Installing dual clutch.................................................................................................................................................................................................................................................................................................................................................................................................................................... 4705
34 – Controls, housing................................................................................................................................................................................................................................................................................................................................................................................................................................................ 4707
1 Mechatronic unit................................................................................................................................................................................................................................................................................................................................................................................................................................................ 4707
1.1 Exploded view - mechatronic unit.......................................................................................................................................................................................................................................................................................................................................................................................................................... 4707
1.2 Removing and installing oil pan........................................................................................................................................................................................................................................................................................................................................................................................................................... 4710
1.3 Removing and installing ATF filter........................................................................................................................................................................................................................................................................................................................................................................................................................ 4711
1.4 Removing and installing mechatronic unit.................................................................................................................................................................................................................................................................................................................................................................................................................. 4712
2 Selector mechanism.............................................................................................................................................................................................................................................................................................................................................................................................................................................. 4714
2.1 Exploded view - selector mechanism........................................................................................................................................................................................................................................................................................................................................................................................................................ 4714
2.2 Exploded view - selector lever handle..................................................................................................................................................................................................................................................................................................................................................................................................................... 4716
2.2.1 Exploded view - selector lever handle, vehicles up to model year 2011 except for Audi RS 5.......................................................................................................................................................................................................................................................................................................................................................... 4716
2.2.2 Exploded view - selector lever handle, vehicles from model year 2012 onwards and Audi RS 5/RS 4..................................................................................................................................................................................................................................................................................................................................................... 4717
2.3 Exploded view - selector lever cable...................................................................................................................................................................................................................................................................................................................................................................................................................... 4718
2.4 Checking selector mechanism............................................................................................................................................................................................................................................................................................................................................................................................................................... 4718
2.5 Manual release from position P............................................................................................................................................................................................................................................................................................................................................................................................................................ 4721
2.6 Removing and installing selector mechanism................................................................................................................................................................................................................................................................................................................................................................................................................ 4722
2.7 Dismantling and assembling selector mechanism............................................................................................................................................................................................................................................................................................................................................................................................................. 4728
2.7.1 Removing and installing selector lever lock solenoid -N110-......................................................................................................................................................................................................................................................................................................................................................................................... 4728
2.7.2 Removing and installing selector lever sensors control unit -J587-.................................................................................................................................................................................................................................................................................................................................................................................. 4730
2.7.3 Removing and installing gear selector position P switch -F305-...................................................................................................................................................................................................................................................................................................................................................................................... 4731
2.8 Removing and installing selector lever handle............................................................................................................................................................................................................................................................................................................................................................................................................. 4731
2.8.1 Removing and installing selector lever handle - vehicles up to model year 2011 except for RS 5...................................................................................................................................................................................................................................................................................................................................................... 4731
2.8.2 Detaching selector lever boot from selector lever handle - vehicles up to model year 2011 except for RS 5........................................................................................................................................................................................................................................................................................................................................... 4734
2.8.3 Removing and installing selector lever handle with interlock button (side) - vehicles from model year 2012 onwards.................................................................................................................................................................................................................................................................................................................................. 4734
2.8.4 Removing and installing selector lever handle with interlock button (front) - vehicles from model year 2012 onwards and RS 5/RS 4................................................................................................................................................................................................................................................................................................................... 4737
2.8.5 Moving interlock button (front) on selector lever handle into installation position - vehicles from model year 2012 onwards and RS 5/RS 4........................................................................................................................................................................................................................................................................................................... 4739
2.9 Removing and installing selector lever position display -Y26-............................................................................................................................................................................................................................................................................................................................................................................................. 4741
2.10 Removing and installing selector lever cable............................................................................................................................................................................................................................................................................................................................................................................................................. 4741
2.11 Checking and adjusting selector lever cable.............................................................................................................................................................................................................................................................................................................................................................................................................. 4747
2.12 Adjusting selector lever cable to basic setting.......................................................................................................................................................................................................................................................................................................................................................................................................... 4748
2.13 Renewing selector shaft oil seal......................................................................................................................................................................................................................................................................................................................................................................................................................... 4751
3 Removing and installing gearbox................................................................................................................................................................................................................................................................................................................................................................................................................................. 4754
3.1 Removing gearbox.......................................................................................................................................................................................................................................................................................................................................................................................................................................... 4754
3.1.1 Removing gearbox - vehicles with 4-cyl. petrol engine............................................................................................................................................................................................................................................................................................................................................................................................... 4754
3.1.2 Removing gearbox - vehicles with 6-cyl. petrol engine............................................................................................................................................................................................................................................................................................................................................................................................... 4765
3.1.3 Removing gearbox - vehicles with 8-cyl. petrol engine (RS 5/RS 4)................................................................................................................................................................................................................................................................................................................................................................................... 4778
3.1.4 Removing gearbox - vehicles with 4-cyl. TDI engine (PR-TH3/TM4)..................................................................................................................................................................................................................................................................................................................................................................................... 4789
3.1.5 Removing gearbox - vehicles with 4-cyl. TDI engine (PR-TD1)......................................................................................................................................................................................................................................................................................................................................................................................... 4798
3.1.6 Removing gearbox - vehicles with 6-cyl. TDI engine.................................................................................................................................................................................................................................................................................................................................................................................................. 4806
3.2 Installing gearbox........................................................................................................................................................................................................................................................................................................................................................................................................................................ 4816
3.3 Tightening torques for gearbox............................................................................................................................................................................................................................................................................................................................................................................................................................ 4826
4 Assembly mountings.............................................................................................................................................................................................................................................................................................................................................................................................................................................. 4829
4.1 Exploded view - assembly mountings........................................................................................................................................................................................................................................................................................................................................................................................................................ 4829
4.2 Removing and installing tunnel cross member............................................................................................................................................................................................................................................................................................................................................................................................................... 4830
4.3 Removing and installing gearbox support with gearbox mounting............................................................................................................................................................................................................................................................................................................................................................................................. 4832
4.4 Removing and installing gearbox mounting.................................................................................................................................................................................................................................................................................................................................................................................................................. 4833
5 Transporting gearbox............................................................................................................................................................................................................................................................................................................................................................................................................................................ 4834
6 Securing to engine and gearbox support.......................................................................................................................................................................................................................................................................................................................................................................................................................... 4835
7 ATF............................................................................................................................................................................................................................................................................................................................................................................................................................................................. 4836
7.1 Exploded view - drain, filler and inspection plugs........................................................................................................................................................................................................................................................................................................................................................................................................ 4836
7.2 Checking ATF level........................................................................................................................................................................................................................................................................................................................................................................................................................................ 4836
7.3 Draining and filling ATF.................................................................................................................................................................................................................................................................................................................................................................................................................................. 4839
8 ATF circuit..................................................................................................................................................................................................................................................................................................................................................................................................................................................... 4843
8.1 Exploded view - ATF circuit............................................................................................................................................................................................................................................................................................................................................................................................................................... 4843
8.1.1 Exploded view - ATF cooler, ATF lines and in-line ATF filter........................................................................................................................................................................................................................................................................................................................................................................................ 4843
8.1.2 Exploded view - ATF cooler, ATF lines and exchangeable ATF filter................................................................................................................................................................................................................................................................................................................................................................................... 4847
8.2 Cleaning ATF lines........................................................................................................................................................................................................................................................................................................................................................................................................................................ 4852
8.3 Removing and installing ATF lines......................................................................................................................................................................................................................................................................................................................................................................................................................... 4854
8.3.1 Removing and installing ATF lines - vehicles with 4-cyl. petrol engine.............................................................................................................................................................................................................................................................................................................................................................................. 4854
8.3.2 Removing and installing ATF lines - vehicles with 4-cylinder TDI engine and with all 6-cylinder engines............................................................................................................................................................................................................................................................................................................................................. 4856
8.3.3 Removing and installing ATF lines - vehicles with 8-cyl. engine..................................................................................................................................................................................................................................................................................................................................................................................... 4858
8.4 Removing and installing ATF filter........................................................................................................................................................................................................................................................................................................................................................................................................................ 4868
8.4.1 Removing and installing in-line ATF filter.......................................................................................................................................................................................................................................................................................................................................................................................................... 4868
8.4.2 Removing and installing exchangeable ATF filter..................................................................................................................................................................................................................................................................................................................................................................................................... 4870
8.5 Removing and installing ATF filter housing and connecting piece for ATF lines............................................................................................................................................................................................................................................................................................................................................................................. 4876
35 – Gears, shafts.................................................................................................................................................................................................................................................................................................................................................................................................................................................... 4879
1 Input shaft..................................................................................................................................................................................................................................................................................................................................................................................................................................................... 4879
1.1 Renewing ball bearing for input shaft..................................................................................................................................................................................................................................................................................................................................................................................................................... 4879
1.2 Renewing input shaft oil seal............................................................................................................................................................................................................................................................................................................................................................................................................................. 4879
39 – Final drive - front differential................................................................................................................................................................................................................................................................................................................................................................................................................................. 4880
1 Final drive..................................................................................................................................................................................................................................................................................................................................................................................................................................................... 4880
1.1 Exploded view - final drive............................................................................................................................................................................................................................................................................................................................................................................................................................... 4880
2 Gear oil........................................................................................................................................................................................................................................................................................................................................................................................................................................................ 4882
2.1 Exploded view - gear oil drain and inspection plugs....................................................................................................................................................................................................................................................................................................................................................................................................... 4882
2.2 Checking gear oil level................................................................................................................................................................................................................................................................................................................................................................................................................................... 4883
2.3 Draining and filling gear oil............................................................................................................................................................................................................................................................................................................................................................................................................................. 4887
2.4 Removing and installing gearbox oil temperature sender 2 -G754-........................................................................................................................................................................................................................................................................................................................................................................................... 4894
3 Oil seals....................................................................................................................................................................................................................................................................................................................................................................................................................................................... 4895
3.1 Renewing oil seal (left-side)............................................................................................................................................................................................................................................................................................................................................................................................................................. 4895
3.2 Renewing oil seal (right-side)............................................................................................................................................................................................................................................................................................................................................................................................................................ 4895
4 Differential.................................................................................................................................................................................................................................................................................................................................................................................................................................................... 4896
4.1 Removing and installing flange shaft (left-side).......................................................................................................................................................................................................................................................................................................................................................................................................... 4896
4.2 Removing and installing flange shaft (right-side)......................................................................................................................................................................................................................................................................................................................................................................................................... 4896
5 Centre differential............................................................................................................................................................................................................................................................................................................................................................................................................................................. 4899
5.1 Exploded view - centre differential housing............................................................................................................................................................................................................................................................................................................................................................................................................... 4899
5.1.1 Exploded view - centre differential housing - bolted propshaft...................................................................................................................................................................................................................................................................................................................................................................................... 4899
5.1.2 Exploded view - centre differential housing - propshaft with splines on gearbox end................................................................................................................................................................................................................................................................................................................................................................. 4901
5.2 Removing and installing centre differential housing....................................................................................................................................................................................................................................................................................................................................................................................................... 4903
5.2.1 Removing and installing centre differential housing - bolted propshaft.............................................................................................................................................................................................................................................................................................................................................................................. 4903
5.2.2 Removing and installing centre differential - vehicles with propshaft with splines on gearbox end................................................................................................................................................................................................................................................................................................................................................... 4910
5.3 Removing and installing rear flange shaft, oil seal and ball bearing for rear flange shaft................................................................................................................................................................................................................................................................................................................................................................ 4915
5.4 Removing and installing rear splined shaft, oil seal and ball bearing..................................................................................................................................................................................................................................................................................................................................................................................... 4915
5.5 Renewing oil seal for rear splined shaft.................................................................................................................................................................................................................................................................................................................................................................................................................. 4915
5.6 Pressing vibration damper onto rear splined shaft......................................................................................................................................................................................................................................................................................................................................................................................................... 4916
5.7 Removing and installing centre differential housing....................................................................................................................................................................................................................................................................................................................................................................................................... 4916
6 Gearbox control system.......................................................................................................................................................................................................................................................................................................................................................................................................................................... 4917
6.1 Overview of fitting locations - gearbox control system.................................................................................................................................................................................................................................................................................................................................................................................................... 4917
6.2 Guided Functions for gearbox.............................................................................................................................................................................................................................................................................................................................................................................................................................. 4921
8-cylinder_direct_injection_engine_(4_2_ltr__4-valve)..................................................................................................................................................................................................................................................................................................................................................................................................................... 4924
00 – Technical data................................................................................................................................................................................................................................................................................................................................................................................................................................................... 4930
1 Identification.................................................................................................................................................................................................................................................................................................................................................................................................................................................. 4930
1.1 Engine identification number/engine data.................................................................................................................................................................................................................................................................................................................................................................................................................. 4930
2 General notes................................................................................................................................................................................................................................................................................................................................................................................................................................................... 4931
2.1 General notes on ignition system.......................................................................................................................................................................................................................................................................................................................................................................................................................... 4931
3 Safety precautions.............................................................................................................................................................................................................................................................................................................................................................................................................................................. 4932
3.1 Safety precautions when working on the fuel system........................................................................................................................................................................................................................................................................................................................................................................................................ 4932
3.2 Safety precautions when working on the fuel supply system................................................................................................................................................................................................................................................................................................................................................................................................. 4933
3.3 Safety precautions when working on vehicles with start/stop system........................................................................................................................................................................................................................................................................................................................................................................................ 4935
3.4 Safety precautions when using testers and measuring instruments during a road test........................................................................................................................................................................................................................................................................................................................................................................ 4935
3.5 Safety precautions when working on the subframe........................................................................................................................................................................................................................................................................................................................................................................................................... 4935
3.6 Safety precautions when working on the cooling system..................................................................................................................................................................................................................................................................................................................................................................................................... 4936
3.7 Safety precautions when working on the ignition system.................................................................................................................................................................................................................................................................................................................................................................................................... 4936
3.8 Safety precautions when working on the exhaust system..................................................................................................................................................................................................................................................................................................................................................................................................... 4937
4 Repair instructions............................................................................................................................................................................................................................................................................................................................................................................................................................................. 4938
4.1 Rules for cleanliness..................................................................................................................................................................................................................................................................................................................................................................................................................................... 4938
4.2 Checking fuel system for leaks............................................................................................................................................................................................................................................................................................................................................................................................................................ 4938
4.3 Foreign particles in engine............................................................................................................................................................................................................................................................................................................................................................................................................................... 4938
4.4 Contact corrosion......................................................................................................................................................................................................................................................................................................................................................................................................................................... 4939
4.5 Installing radiators and condensers....................................................................................................................................................................................................................................................................................................................................................................................................................... 4939
4.6 Routing and attachment of pipes, hoses and wiring......................................................................................................................................................................................................................................................................................................................................................................................................... 4939
4.7 Checking vacuum system.................................................................................................................................................................................................................................................................................................................................................................................................................................... 4939
5 Technical data.................................................................................................................................................................................................................................................................................................................................................................................................................................................. 4941
5.1 Technical data of injection system........................................................................................................................................................................................................................................................................................................................................................................................................................ 4941
10 – Removing and installing engine................................................................................................................................................................................................................................................................................................................................................................................................................................... 4942
1 Removing and installing engine.................................................................................................................................................................................................................................................................................................................................................................................................................................. 4942
1.1 Removing engine........................................................................................................................................................................................................................................................................................................................................................................................................................................... 4942
1.1.1 Removing engine - vehicles with manual gearbox...................................................................................................................................................................................................................................................................................................................................................................................................... 4942
1.1.2 Removing engine - vehicles with automatic gearbox................................................................................................................................................................................................................................................................................................................................................................................................... 4961
1.2 Separating engine and gearbox............................................................................................................................................................................................................................................................................................................................................................................................................................. 4980
1.2.1 Separating engine and gearbox - vehicles with manual gearbox........................................................................................................................................................................................................................................................................................................................................................................................ 4980
1.2.2 Separating engine and gearbox - vehicles with automatic gearbox..................................................................................................................................................................................................................................................................................................................................................................................... 4984
1.3 Securing engine to engine and gearbox support............................................................................................................................................................................................................................................................................................................................................................................................................. 4989
1.4 Installing engine......................................................................................................................................................................................................................................................................................................................................................................................................................................... 4993
1.4.1 Installing engine, vehicles with manual gearbox..................................................................................................................................................................................................................................................................................................................................................................................................... 4993
1.4.2 Installing engine - vehicles with automatic gearbox................................................................................................................................................................................................................................................................................................................................................................................................. 5000
2 Assembly mountings.............................................................................................................................................................................................................................................................................................................................................................................................................................................. 5009
2.1 Exploded view - assembly mountings........................................................................................................................................................................................................................................................................................................................................................................................................................ 5009
2.2 Removing and installing engine mountings.................................................................................................................................................................................................................................................................................................................................................................................................................. 5010
2.2.1 Removing and installing engine mounting (left-side)................................................................................................................................................................................................................................................................................................................................................................................................. 5010
2.2.2 Removing and installing engine mounting (right-side)................................................................................................................................................................................................................................................................................................................................................................................................ 5017
3 Engine cover panel.............................................................................................................................................................................................................................................................................................................................................................................................................................................. 5021
3.1 Removing and installing engine cover panel................................................................................................................................................................................................................................................................................................................................................................................................................ 5021
13 – Crankshaft group................................................................................................................................................................................................................................................................................................................................................................................................................................................. 5022
1 Cylinder block (pulley end)..................................................................................................................................................................................................................................................................................................................................................................................................................................... 5022
1.1 Exploded view - poly V-belt drive......................................................................................................................................................................................................................................................................................................................................................................................................................... 5022
1.2 Removing and installing poly V-belt....................................................................................................................................................................................................................................................................................................................................................................................................................... 5023
1.3 Removing and installing tensioner for poly V-belt......................................................................................................................................................................................................................................................................................................................................................................................................... 5024
1.4 Removing and installing vibration damper.................................................................................................................................................................................................................................................................................................................................................................................................................. 5025
1.5 Renewing crankshaft oil seal (pulley end)................................................................................................................................................................................................................................................................................................................................................................................................................. 5025
2 Cylinder block (gearbox end).................................................................................................................................................................................................................................................................................................................................................................................................................................... 5028
2.1 Exploded view - drive plate............................................................................................................................................................................................................................................................................................................................................................................................................................... 5028
2.2 Removing and installing drive plate....................................................................................................................................................................................................................................................................................................................................................................................................................... 5028
2.3 Renewing crankshaft oil seal (gearbox end)................................................................................................................................................................................................................................................................................................................................................................................................................ 5029
2.4 Renewing needle bearing in drive plate.................................................................................................................................................................................................................................................................................................................................................................................................................... 5031
2.4.1 Renewing needle bearing in drive plate - vehicles with manual gearbox............................................................................................................................................................................................................................................................................................................................................................................... 5031
3 Crankshaft...................................................................................................................................................................................................................................................................................................................................................................................................................................................... 5033
3.1 Exploded view - crankshaft................................................................................................................................................................................................................................................................................................................................................................................................................................ 5033
3.2 Crankshaft dimensions..................................................................................................................................................................................................................................................................................................................................................................................................................................... 5036
3.3 Allocation of main bearing shells......................................................................................................................................................................................................................................................................................................................................................................................................................... 5036
3.4 Measuring axial clearance of crankshaft................................................................................................................................................................................................................................................................................................................................................................................................................... 5038
3.5 Measuring radial clearance of crankshaft.................................................................................................................................................................................................................................................................................................................................................................................................................. 5039
4 Auxiliary drive................................................................................................................................................................................................................................................................................................................................................................................................................................................. 5040
4.1 Exploded view - auxiliary drive........................................................................................................................................................................................................................................................................................................................................................................................................................... 5040
4.2 Removing and installing spur gear drive................................................................................................................................................................................................................................................................................................................................................................................................................... 5041
4.3 Renewing oil seal for power steering pump drive........................................................................................................................................................................................................................................................................................................................................................................................................... 5044
4.4 Renewing oil seal for AC compressor drive................................................................................................................................................................................................................................................................................................................................................................................................................. 5045
5 Pistons and conrods............................................................................................................................................................................................................................................................................................................................................................................................................................................. 5048
5.1 Exploded view - pistons and conrods....................................................................................................................................................................................................................................................................................................................................................................................................................... 5048
5.2 Removing and installing pistons........................................................................................................................................................................................................................................................................................................................................................................................................................... 5050
5.3 Checking pistons and cylinder bores....................................................................................................................................................................................................................................................................................................................................................................................................................... 5051
5.4 Checking radial clearance of conrod bearings.............................................................................................................................................................................................................................................................................................................................................................................................................. 5052
15 – Cylinder head, valve gear........................................................................................................................................................................................................................................................................................................................................................................................................................................ 5054
1 Cylinder head................................................................................................................................................................................................................................................................................................................................................................................................................................................... 5054
1.1 Exploded view - cylinder head............................................................................................................................................................................................................................................................................................................................................................................................................................. 5054
1.2 Removing and installing cylinder head..................................................................................................................................................................................................................................................................................................................................................................................................................... 5056
1.2.1 Removing cylinder head (left-side).................................................................................................................................................................................................................................................................................................................................................................................................................. 5056
1.2.2 Removing cylinder head (right-side)................................................................................................................................................................................................................................................................................................................................................................................................................. 5058
1.2.3 Installing cylinder head............................................................................................................................................................................................................................................................................................................................................................................................................................ 5059
1.3 Removing and installing cylinder head cover............................................................................................................................................................................................................................................................................................................................................................................................................... 5063
1.3.1 Removing and installing cylinder head cover (left-side)............................................................................................................................................................................................................................................................................................................................................................................................. 5063
1.3.2 Removing and installing cylinder head cover (right-side)............................................................................................................................................................................................................................................................................................................................................................................................ 5064
1.4 Checking compression...................................................................................................................................................................................................................................................................................................................................................................................................................................... 5066
2 Timing chain cover.............................................................................................................................................................................................................................................................................................................................................................................................................................................. 5071
2.1 Exploded view - timing chain cover........................................................................................................................................................................................................................................................................................................................................................................................................................ 5071
2.2 Removing and installing timing chain cover................................................................................................................................................................................................................................................................................................................................................................................................................ 5073
2.2.1 Removing and installing timing chain cover (left-side).............................................................................................................................................................................................................................................................................................................................................................................................. 5073
2.2.2 Removing and installing timing chain cover (right-side)............................................................................................................................................................................................................................................................................................................................................................................................. 5075
2.2.3 Removing and installing timing chain cover (bottom)................................................................................................................................................................................................................................................................................................................................................................................................. 5080
3 Chain drive..................................................................................................................................................................................................................................................................................................................................................................................................................................................... 5086
3.1 Exploded view - camshaft timing chains.................................................................................................................................................................................................................................................................................................................................................................................................................... 5086
3.2 Exploded view - drive chain for valve gear................................................................................................................................................................................................................................................................................................................................................................................................................ 5089
3.3 Exploded view - drive chain for auxiliary drives.......................................................................................................................................................................................................................................................................................................................................................................................................... 5090
3.4 Removing and installing camshaft timing chain............................................................................................................................................................................................................................................................................................................................................................................................................. 5090
3.5 Removing camshaft timing chain from camshafts............................................................................................................................................................................................................................................................................................................................................................................................................. 5092
3.6 Removing and installing drive chain for valve gear........................................................................................................................................................................................................................................................................................................................................................................................................ 5100
3.7 Removing and installing drive chain for auxiliary drive................................................................................................................................................................................................................................................................................................................................................................................................... 5102
4 Valve gear...................................................................................................................................................................................................................................................................................................................................................................................................................................................... 5103
4.1 Exploded view - valve gear................................................................................................................................................................................................................................................................................................................................................................................................................................ 5103
4.2 Measuring axial clearance of camshaft..................................................................................................................................................................................................................................................................................................................................................................................................................... 5106
4.3 Measuring radial clearance of camshaft.................................................................................................................................................................................................................................................................................................................................................................................................................... 5106
4.4 Removing and installing camshaft.......................................................................................................................................................................................................................................................................................................................................................................................................................... 5107
4.5 Checking hydraulic valve compensation elements............................................................................................................................................................................................................................................................................................................................................................................................................ 5116
4.6 Removing and installing valve stem oil seals.............................................................................................................................................................................................................................................................................................................................................................................................................. 5118
4.6.1 Renewing valve stem oil seals with cylinder head installed.......................................................................................................................................................................................................................................................................................................................................................................................... 5118
4.6.2 Renewing valve stem oil seals with cylinder head removed............................................................................................................................................................................................................................................................................................................................................................................................ 5122
5 Inlet and exhaust valves........................................................................................................................................................................................................................................................................................................................................................................................................................................ 5127
5.1 Checking valve guides..................................................................................................................................................................................................................................................................................................................................................................................................................................... 5127
5.2 Checking valves........................................................................................................................................................................................................................................................................................................................................................................................................................................... 5128
5.3 Valve dimensions.......................................................................................................................................................................................................................................................................................................................................................................................................................................... 5129
17 – Lubrication...................................................................................................................................................................................................................................................................................................................................................................................................................................................... 5130
1 Sump/oil pump................................................................................................................................................................................................................................................................................................................................................................................................................................................... 5130
1.1 Exploded view - sump/oil pump............................................................................................................................................................................................................................................................................................................................................................................................................................. 5130
1.2 Exploded view - sump (top section)........................................................................................................................................................................................................................................................................................................................................................................................................................ 5133
1.3 Engine oil................................................................................................................................................................................................................................................................................................................................................................................................................................................ 5134
1.4 Removing and installing sump (bottom section)............................................................................................................................................................................................................................................................................................................................................................................................................. 5134
1.5 Removing and installing sump (top section)................................................................................................................................................................................................................................................................................................................................................................................................................ 5136
1.6 Removing and installing oil pump.......................................................................................................................................................................................................................................................................................................................................................................................................................... 5138
1.6.1 Removing and installing oil pump up to engine number CAUA 003 685................................................................................................................................................................................................................................................................................................................................................................................... 5138
1.6.2 Removing and installing oil pump from engine number CAUA 003 686 onwards............................................................................................................................................................................................................................................................................................................................................................................ 5141
1.7 Removing and installing oil level and oil temperature sender -G266-....................................................................................................................................................................................................................................................................................................................................................................................... 5143
1.8 Checking oil level........................................................................................................................................................................................................................................................................................................................................................................................................................................ 5143
2 Engine oil cooler............................................................................................................................................................................................................................................................................................................................................................................................................................................... 5144
2.1 Removing and installing engine oil cooler................................................................................................................................................................................................................................................................................................................................................................................................................. 5144
3 Crankcase breather.............................................................................................................................................................................................................................................................................................................................................................................................................................................. 5146
3.1 Removing and installing hose for crankcase breather system................................................................................................................................................................................................................................................................................................................................................................................................ 5146
4 Oil filter/oil pressure switch.................................................................................................................................................................................................................................................................................................................................................................................................................................. 5147
4.1 Exploded view - oil filter housing/oil pressure switch.................................................................................................................................................................................................................................................................................................................................................................................................... 5147
4.2 Removing and installing oil pressure switch -F1-.......................................................................................................................................................................................................................................................................................................................................................................................................... 5148
4.3 Checking oil pressure and oil pressure switch............................................................................................................................................................................................................................................................................................................................................................................................................. 5148
4.4 Removing and installing oil filter housing................................................................................................................................................................................................................................................................................................................................................................................................................ 5150
5 Oil circuit..................................................................................................................................................................................................................................................................................................................................................................................................................................................... 5152
5.1 Exploded view - oil spray jets/valves..................................................................................................................................................................................................................................................................................................................................................................................................................... 5152
5.2 Removing and installing oil spray jets/valves............................................................................................................................................................................................................................................................................................................................................................................................................. 5152
19 – Cooling.......................................................................................................................................................................................................................................................................................................................................................................................................................................................... 5154
1 Cooling system/coolant.......................................................................................................................................................................................................................................................................................................................................................................................................................................... 5154
1.1 Connection diagram - coolant hoses........................................................................................................................................................................................................................................................................................................................................................................................................................ 5154
1.2 Checking cooling system for leaks......................................................................................................................................................................................................................................................................................................................................................................................................................... 5156
1.3 Draining and filling cooling system....................................................................................................................................................................................................................................................................................................................................................................................................................... 5158
2 Coolant pump/thermostat assembly................................................................................................................................................................................................................................................................................................................................................................................................................................ 5165
2.1 Exploded view - coolant pump and thermostat............................................................................................................................................................................................................................................................................................................................................................................................................... 5165
2.2 Removing and installing electric coolant pump............................................................................................................................................................................................................................................................................................................................................................................................................. 5166
2.2.1 Removing and installing continued coolant circulation pump -V51-.................................................................................................................................................................................................................................................................................................................................................................................... 5166
2.3 Removing and installing coolant pump...................................................................................................................................................................................................................................................................................................................................................................................................................... 5168
2.4 Removing and installing map-controlled engine cooling system thermostat -F265-............................................................................................................................................................................................................................................................................................................................................................................ 5169
2.5 Removing and installing coolant temperature sender -G62-.................................................................................................................................................................................................................................................................................................................................................................................................. 5171
2.6 Removing and installing coolant connection................................................................................................................................................................................................................................................................................................................................................................................................................ 5172
2.7 Thermostat opening values................................................................................................................................................................................................................................................................................................................................................................................................................................. 5174
3 Coolant pipes................................................................................................................................................................................................................................................................................................................................................................................................................................................... 5175
3.1 Exploded view - coolant pipes............................................................................................................................................................................................................................................................................................................................................................................................................................. 5175
3.2 Removing and installing coolant pipes..................................................................................................................................................................................................................................................................................................................................................................................................................... 5176
3.2.1 Removing and installing coolant pipe (front)........................................................................................................................................................................................................................................................................................................................................................................................................ 5176
3.2.2 Removing and installing coolant pipe (top left)..................................................................................................................................................................................................................................................................................................................................................................................................... 5177
3.2.3 Removing and installing coolant pipe (bottom left).................................................................................................................................................................................................................................................................................................................................................................................................. 5181
3.2.4 Removing and installing coolant pipe (right-side)................................................................................................................................................................................................................................................................................................................................................................................................... 5182
3.2.5 Removing and installing coolant pipe (rear)......................................................................................................................................................................................................................................................................................................................................................................................................... 5183
4 Radiator/radiator fans.......................................................................................................................................................................................................................................................................................................................................................................................................................................... 5185
4.1 Exploded view - radiator/radiator fans.................................................................................................................................................................................................................................................................................................................................................................................................................... 5185
4.2 Removing and installing radiator.......................................................................................................................................................................................................................................................................................................................................................................................................................... 5186
4.3 Removing and installing radiator cowl..................................................................................................................................................................................................................................................................................................................................................................................................................... 5190
4.4 Removing and installing radiator fans..................................................................................................................................................................................................................................................................................................................................................................................................................... 5193
24 – Mixture preparation - injection.................................................................................................................................................................................................................................................................................................................................................................................................................................. 5194
1 Injection system................................................................................................................................................................................................................................................................................................................................................................................................................................................ 5194
1.1 Overview of fitting locations - injection system.......................................................................................................................................................................................................................................................................................................................................................................................................... 5194
2 Vacuum system................................................................................................................................................................................................................................................................................................................................................................................................................................................... 5205
2.1 Connection diagram - vacuum system........................................................................................................................................................................................................................................................................................................................................................................................................................ 5205
2.1.1 Connection diagram - vacuum system, plastic intake manifold (gradual introduction in model year 2009)............................................................................................................................................................................................................................................................................................................................................... 5205
3 Injectors....................................................................................................................................................................................................................................................................................................................................................................................................................................................... 5206
3.1 Exploded view - fuel rail with injectors.................................................................................................................................................................................................................................................................................................................................................................................................................. 5206
3.1.1 Exploded view - fuel rail with injectors, magnesium intake manifold................................................................................................................................................................................................................................................................................................................................................................................. 5206
3.1.2 Exploded view - fuel rail with injectors, plastic intake manifold (gradual introduction in model year 2009)......................................................................................................................................................................................................................................................................................................................................... 5208
3.2 Removing and installing injectors......................................................................................................................................................................................................................................................................................................................................................................................................................... 5209
3.2.1 Removing and installing injectors - magnesium intake manifold....................................................................................................................................................................................................................................................................................................................................................................................... 5209
3.2.2 Removing and installing injectors - plastic intake manifold (gradual introduction in model year 2009)............................................................................................................................................................................................................................................................................................................................................... 5213
4 Air cleaner..................................................................................................................................................................................................................................................................................................................................................................................................................................................... 5218
4.1 Exploded view - air cleaner housing....................................................................................................................................................................................................................................................................................................................................................................................................................... 5218
4.2 Removing and installing air cleaner housing............................................................................................................................................................................................................................................................................................................................................................................................................... 5220
4.2.1 Removing and installing air filter element.......................................................................................................................................................................................................................................................................................................................................................................................................... 5220
4.2.2 Removing air cleaner (bottom section)............................................................................................................................................................................................................................................................................................................................................................................................................... 5221
5 Intake manifold................................................................................................................................................................................................................................................................................................................................................................................................................................................. 5225
5.1 Exploded view - intake manifold........................................................................................................................................................................................................................................................................................................................................................................................................................... 5225
5.1.1 Exploded view - magnesium intake manifold........................................................................................................................................................................................................................................................................................................................................................................................................... 5225
5.1.2 Exploded view - plastic intake manifold (gradual introduction in model year 2009)................................................................................................................................................................................................................................................................................................................................................................... 5227
5.2 Exploded view - intake manifold (bottom section) with fuel rail........................................................................................................................................................................................................................................................................................................................................................................................... 5229
5.2.1 Exploded view - plastic intake manifold (bottom section) with fuel rail (gradual introduction in model year 2009)................................................................................................................................................................................................................................................................................................................................... 5229
5.3 Removing and installing intake manifold (bottom section) with fuel rail................................................................................................................................................................................................................................................................................................................................................................................... 5230
5.3.1 Removing and installing intake manifold (bottom section) with fuel rail - plastic intake manifold (gradual introduction in model year 2009)......................................................................................................................................................................................................................................................................................................... 5230
5.4 Removing and installing intake manifold................................................................................................................................................................................................................................................................................................................................................................................................................... 5234
5.4.1 Removing and installing magnesium intake manifold................................................................................................................................................................................................................................................................................................................................................................................................... 5234
5.4.2 Removing and installing plastic intake manifold (gradual introduction in model year 2009)........................................................................................................................................................................................................................................................................................................................................................... 5239
6 Senders and sensors............................................................................................................................................................................................................................................................................................................................................................................................................................................. 5245
6.1 Removing and installing fuel pressure sender -G247-....................................................................................................................................................................................................................................................................................................................................................................................................... 5245
6.2 Removing and installing air mass meter.................................................................................................................................................................................................................................................................................................................................................................................................................... 5246
7 Engine control unit............................................................................................................................................................................................................................................................................................................................................................................................................................................. 5247
7.1 Wiring and component check with test box -V.A.G 1598/42-.................................................................................................................................................................................................................................................................................................................................................................................................. 5247
7.2 Removing and installing engine control unit -J623-........................................................................................................................................................................................................................................................................................................................................................................................................ 5249
8 High-pressure pump.............................................................................................................................................................................................................................................................................................................................................................................................................................................. 5253
8.1 Exploded view - high-pressure pump........................................................................................................................................................................................................................................................................................................................................................................................................................ 5253
8.2 Removing and installing high-pressure pump................................................................................................................................................................................................................................................................................................................................................................................................................ 5255
8.3 Removing and installing high-pressure pipe................................................................................................................................................................................................................................................................................................................................................................................................................ 5257
8.4 Checking fuel pressure and residual pressure (up to high-pressure pump)................................................................................................................................................................................................................................................................................................................................................................................... 5259
9 Lambda probe.................................................................................................................................................................................................................................................................................................................................................................................................................................................... 5263
9.1 Exploded view - Lambda probe.............................................................................................................................................................................................................................................................................................................................................................................................................................. 5263
9.2 Removing and installing Lambda probe...................................................................................................................................................................................................................................................................................................................................................................................................................... 5264
9.2.1 Removing and installing Lambda probe -G39- / Lambda probe after catalytic converter -G130-, cylinder bank 1......................................................................................................................................................................................................................................................................................................................................... 5264
9.2.2 Removing and installing Lambda probe 2 -G108- / Lambda probe after catalytic converter -G131-, cylinder bank 2...................................................................................................................................................................................................................................................................................................................................... 5266
26 – Exhaust system................................................................................................................................................................................................................................................................................................................................................................................................................................................... 5268
1 Exhaust pipes/silencers......................................................................................................................................................................................................................................................................................................................................................................................................................................... 5268
1.1 Exploded view - silencers................................................................................................................................................................................................................................................................................................................................................................................................................................. 5268
1.2 Removing and installing front silencer.................................................................................................................................................................................................................................................................................................................................................................................................................... 5271
1.3 Separating exhaust pipes/silencers........................................................................................................................................................................................................................................................................................................................................................................................................................ 5272
1.4 Renewing tailpipes........................................................................................................................................................................................................................................................................................................................................................................................................................................ 5273
1.5 Stress-free alignment of exhaust system................................................................................................................................................................................................................................................................................................................................................................................................................... 5274
1.6 Checking exhaust system for leaks......................................................................................................................................................................................................................................................................................................................................................................................................................... 5275
1.7 Aligning tailpipes........................................................................................................................................................................................................................................................................................................................................................................................................................................ 5275
2 Emission control system......................................................................................................................................................................................................................................................................................................................................................................................................................................... 5276
2.1 Removing and installing catalytic converter............................................................................................................................................................................................................................................................................................................................................................................................................... 5276
2.1.1 Removing and installing catalytic converter (left-side)............................................................................................................................................................................................................................................................................................................................................................................................. 5276
2.1.2 Removing and installing catalytic converter (right-side) - vehicles with manual gearbox............................................................................................................................................................................................................................................................................................................................................................. 5279
2.1.3 Removing and installing catalytic converter (right-side) - vehicles with automatic gearbox.......................................................................................................................................................................................................................................................................................................................................................... 5279
3 Secondary air system............................................................................................................................................................................................................................................................................................................................................................................................................................................ 5282
3.1 Exploded view - secondary air system...................................................................................................................................................................................................................................................................................................................................................................................................................... 5282
3.1.1 Exploded view - secondary air system without vacuum control......................................................................................................................................................................................................................................................................................................................................................................................... 5282
3.1.2 Exploded view - secondary air system with vacuum control............................................................................................................................................................................................................................................................................................................................................................................................ 5284
3.2 Removing and installing secondary air pump motor -V101-................................................................................................................................................................................................................................................................................................................................................................................................... 5286
3.2.1 Removing and installing secondary air pump motor -V101- - system without vacuum control............................................................................................................................................................................................................................................................................................................................................................. 5286
3.2.2 Removing and installing secondary air pump motor -V101- - system with vacuum control................................................................................................................................................................................................................................................................................................................................................................ 5288
3.3 Checking secondary air inlet valve........................................................................................................................................................................................................................................................................................................................................................................................................................ 5290
3.3.1 Checking secondary air inlet valve - system without vacuum control.................................................................................................................................................................................................................................................................................................................................................................................. 5290
3.3.2 Checking secondary air inlet valve - system with vacuum control..................................................................................................................................................................................................................................................................................................................................................................................... 5292
3.4 Removing and installing combination valve................................................................................................................................................................................................................................................................................................................................................................................................................. 5294
3.4.1 Removing and installing combination valve (left-side) - system without vacuum control............................................................................................................................................................................................................................................................................................................................................................... 5294
3.4.2 Removing and installing combination valve (right-side) - system without vacuum control.............................................................................................................................................................................................................................................................................................................................................................. 5295
3.4.3 Removing and installing combination valve (left-side) - system with vacuum control.................................................................................................................................................................................................................................................................................................................................................................. 5296
3.4.4 Removing and installing combination valve (right-side) - system with vacuum control................................................................................................................................................................................................................................................................................................................................................................. 5297
4 Exhaust manifolds............................................................................................................................................................................................................................................................................................................................................................................................................................................... 5299
4.1 Exploded view - exhaust manifold.......................................................................................................................................................................................................................................................................................................................................................................................................................... 5299
4.2 Removing and installing exhaust manifolds................................................................................................................................................................................................................................................................................................................................................................................................................. 5300
4.2.1 Removing and installing exhaust manifold (left-side)................................................................................................................................................................................................................................................................................................................................................................................................ 5300
4.2.2 Removing and installing exhaust manifold (right-side)............................................................................................................................................................................................................................................................................................................................................................................................... 5302
28 – Ignition system.................................................................................................................................................................................................................................................................................................................................................................................................................................................. 5308
1 Ignition system................................................................................................................................................................................................................................................................................................................................................................................................................................................. 5308
1.1 Exploded view - ignition system........................................................................................................................................................................................................................................................................................................................................................................................................................... 5308
1.2 Test data, spark plugs.................................................................................................................................................................................................................................................................................................................................................................................................................................... 5309
1.3 Removing and installing ignition coils.................................................................................................................................................................................................................................................................................................................................................................................................................... 5309
1.4 Removing and installing knock sensor...................................................................................................................................................................................................................................................................................................................................................................................................................... 5311
1.5 Removing and installing Hall senders...................................................................................................................................................................................................................................................................................................................................................................................................................... 5312
1.6 Removing and installing engine speed sender -G28-......................................................................................................................................................................................................................................................................................................................................................................................................... 5313
8-cylinder_direct_injection_engine_(4_2_ltr__4-valve__RS4__RS5)........................................................................................................................................................................................................................................................................................................................................................................................................... 5314
00 – Technical data................................................................................................................................................................................................................................................................................................................................................................................................................................................... 5320
1 Identification.................................................................................................................................................................................................................................................................................................................................................................................................................................................. 5320
1.1 Engine identification number/engine data.................................................................................................................................................................................................................................................................................................................................................................................................................. 5321
2 General notes................................................................................................................................................................................................................................................................................................................................................................................................................................................... 5322
2.1 Rules for cleanliness when working on the auxiliary/supplementary heater and the fuel system.............................................................................................................................................................................................................................................................................................................................................................. 5322
2.2 General notes on self-diagnosis........................................................................................................................................................................................................................................................................................................................................................................................................................... 5322
2.3 General notes on ignition system.......................................................................................................................................................................................................................................................................................................................................................................................................................... 5322
3 Safety precautions.............................................................................................................................................................................................................................................................................................................................................................................................................................................. 5324
3.1 Safety precautions when working on the fuel system........................................................................................................................................................................................................................................................................................................................................................................................................ 5324
3.2 Safety precautions when working on the cooling system..................................................................................................................................................................................................................................................................................................................................................................................................... 5325
3.3 Safety precautions when working on vehicles with start/stop system........................................................................................................................................................................................................................................................................................................................................................................................ 5325
3.4 Safety precautions when using testers and measuring instruments during a road test........................................................................................................................................................................................................................................................................................................................................................................ 5326
3.5 Safety precautions when working on the exhaust system..................................................................................................................................................................................................................................................................................................................................................................................................... 5326
3.6 Safety precautions when working on the subframe........................................................................................................................................................................................................................................................................................................................................................................................................... 5326
3.7 Safety precautions when working on the ignition system.................................................................................................................................................................................................................................................................................................................................................................................................... 5327
4 Repair instructions............................................................................................................................................................................................................................................................................................................................................................................................................................................. 5329
4.1 Foreign particles in engine............................................................................................................................................................................................................................................................................................................................................................................................................................... 5329
4.2 Contact corrosion......................................................................................................................................................................................................................................................................................................................................................................................................................................... 5329
4.3 Routing and attachment of pipes, hoses and wiring......................................................................................................................................................................................................................................................................................................................................................................................................... 5329
4.4 Installing radiators and condensers....................................................................................................................................................................................................................................................................................................................................................................................................................... 5329
4.5 Checking vacuum system.................................................................................................................................................................................................................................................................................................................................................................................................................................... 5329
5 Technical data.................................................................................................................................................................................................................................................................................................................................................................................................................................................. 5331
5.1 Technical data of injection system........................................................................................................................................................................................................................................................................................................................................................................................................................ 5331
10 – Removing and installing engine................................................................................................................................................................................................................................................................................................................................................................................................................................... 5332
1 Removing and installing engine.................................................................................................................................................................................................................................................................................................................................................................................................................................. 5332
1.1 Removing engine........................................................................................................................................................................................................................................................................................................................................................................................................................................... 5332
1.2 Separating engine and gearbox............................................................................................................................................................................................................................................................................................................................................................................................................................. 5352
1.3 Securing engine to engine and gearbox support............................................................................................................................................................................................................................................................................................................................................................................................................. 5359
1.4 Installing engine......................................................................................................................................................................................................................................................................................................................................................................................................................................... 5363
2 Assembly mountings.............................................................................................................................................................................................................................................................................................................................................................................................................................................. 5371
2.1 Exploded view - assembly mountings........................................................................................................................................................................................................................................................................................................................................................................................................................ 5371
2.2 Removing and installing engine mountings.................................................................................................................................................................................................................................................................................................................................................................................................................. 5372
2.2.1 Removing and installing engine mounting (left-side)................................................................................................................................................................................................................................................................................................................................................................................................. 5372
2.2.2 Removing and installing engine mounting (right-side)................................................................................................................................................................................................................................................................................................................................................................................................ 5379
3 Engine cover panel.............................................................................................................................................................................................................................................................................................................................................................................................................................................. 5382
3.1 Removing and installing engine cover panel................................................................................................................................................................................................................................................................................................................................................................................................................ 5382
13 – Crankshaft group................................................................................................................................................................................................................................................................................................................................................................................................................................................. 5383
1 Cylinder block (pulley end)..................................................................................................................................................................................................................................................................................................................................................................................................................................... 5383
1.1 Exploded view - poly V-belt drive......................................................................................................................................................................................................................................................................................................................................................................................................................... 5383
1.2 Removing and installing poly V-belt....................................................................................................................................................................................................................................................................................................................................................................................................................... 5385
1.3 Removing and installing tensioner for poly V-belt......................................................................................................................................................................................................................................................................................................................................................................................................... 5386
1.4 Removing and installing vibration damper.................................................................................................................................................................................................................................................................................................................................................................................................................. 5386
1.5 Removing and installing bracket for ancillaries........................................................................................................................................................................................................................................................................................................................................................................................................... 5387
1.6 Renewing crankshaft oil seal (pulley end)................................................................................................................................................................................................................................................................................................................................................................................................................. 5387
2 Cylinder block (gearbox end).................................................................................................................................................................................................................................................................................................................................................................................................................................... 5390
2.1 Exploded view - drive plate............................................................................................................................................................................................................................................................................................................................................................................................................................... 5390
2.2 Removing and installing drive plate....................................................................................................................................................................................................................................................................................................................................................................................................................... 5390
2.3 Renewing crankshaft oil seal (gearbox end)................................................................................................................................................................................................................................................................................................................................................................................................................ 5391
3 Crankshaft...................................................................................................................................................................................................................................................................................................................................................................................................................................................... 5394
3.1 Exploded view - crankshaft................................................................................................................................................................................................................................................................................................................................................................................................................................ 5394
3.2 Allocation of main bearing shells......................................................................................................................................................................................................................................................................................................................................................................................................................... 5397
3.3 Crankshaft dimensions..................................................................................................................................................................................................................................................................................................................................................................................................................................... 5399
3.4 Measuring axial clearance of crankshaft................................................................................................................................................................................................................................................................................................................................................................................................................... 5399
3.5 Measuring radial clearance of crankshaft.................................................................................................................................................................................................................................................................................................................................................................................................................. 5400
4 Auxiliary drive................................................................................................................................................................................................................................................................................................................................................................................................................................................. 5401
4.1 Exploded view - auxiliary drive........................................................................................................................................................................................................................................................................................................................................................................................................................... 5401
4.2 Removing and installing spur gear drive................................................................................................................................................................................................................................................................................................................................................................................................................... 5402
4.3 Renewing oil seal for power steering pump drive........................................................................................................................................................................................................................................................................................................................................................................................................... 5405
4.4 Renewing oil seal for AC compressor drive................................................................................................................................................................................................................................................................................................................................................................................................................. 5406
5 Pistons and conrods............................................................................................................................................................................................................................................................................................................................................................................................................................................. 5409
5.1 Exploded view - pistons and conrods....................................................................................................................................................................................................................................................................................................................................................................................................................... 5409
5.2 Removing and installing pistons........................................................................................................................................................................................................................................................................................................................................................................................................................... 5411
5.3 Checking pistons and cylinder bores....................................................................................................................................................................................................................................................................................................................................................................................................................... 5412
5.4 Checking radial clearance of conrod bearings.............................................................................................................................................................................................................................................................................................................................................................................................................. 5413
15 – Cylinder head, valve gear........................................................................................................................................................................................................................................................................................................................................................................................................................................ 5415
1 Cylinder head................................................................................................................................................................................................................................................................................................................................................................................................................................................... 5415
1.1 Exploded view - cylinder head............................................................................................................................................................................................................................................................................................................................................................................................................................. 5415
1.2 Removing and installing cylinder head..................................................................................................................................................................................................................................................................................................................................................................................................................... 5417
1.3 Removing and installing cylinder head cover............................................................................................................................................................................................................................................................................................................................................................................................................... 5423
1.4 Checking compression...................................................................................................................................................................................................................................................................................................................................................................................................................................... 5425
2 Timing chain cover.............................................................................................................................................................................................................................................................................................................................................................................................................................................. 5428
2.1 Exploded view - timing chain cover........................................................................................................................................................................................................................................................................................................................................................................................................................ 5428
2.2 Removing and installing timing chain cover (left-side).................................................................................................................................................................................................................................................................................................................................................................................................... 5430
2.3 Removing and installing timing chain cover (right-side)................................................................................................................................................................................................................................................................................................................................................................................................... 5433
2.4 Removing and installing timing chain cover (bottom)....................................................................................................................................................................................................................................................................................................................................................................................................... 5435
3 Chain drive..................................................................................................................................................................................................................................................................................................................................................................................................................................................... 5440
3.1 Exploded view - camshaft timing chains.................................................................................................................................................................................................................................................................................................................................................................................................................... 5440
3.2 Exploded view - drive chain for valve gear................................................................................................................................................................................................................................................................................................................................................................................................................ 5443
3.3 Exploded view - drive chain for auxiliary drives.......................................................................................................................................................................................................................................................................................................................................................................................................... 5445
3.4 Removing and installing camshaft timing chain............................................................................................................................................................................................................................................................................................................................................................................................................. 5445
3.5 Removing camshaft timing chain from camshafts............................................................................................................................................................................................................................................................................................................................................................................................................. 5447
3.6 Removing and installing drive chain for valve gear........................................................................................................................................................................................................................................................................................................................................................................................................ 5455
3.7 Removing and installing drive chain for auxiliary drive................................................................................................................................................................................................................................................................................................................................................................................................... 5456
4 Valve gear...................................................................................................................................................................................................................................................................................................................................................................................................................................................... 5458
4.1 Exploded view - valve gear................................................................................................................................................................................................................................................................................................................................................................................................................................ 5458
4.2 Measuring axial clearance of camshaft..................................................................................................................................................................................................................................................................................................................................................................................................................... 5461
4.3 Measuring radial clearance of camshaft.................................................................................................................................................................................................................................................................................................................................................................................................................... 5461
4.4 Removing and installing camshaft.......................................................................................................................................................................................................................................................................................................................................................................................................................... 5462
4.5 Checking hydraulic valve compensation elements............................................................................................................................................................................................................................................................................................................................................................................................................ 5471
4.6 Removing and installing valve stem oil seals.............................................................................................................................................................................................................................................................................................................................................................................................................. 5473
4.6.1 Renewing valve stem oil seals with cylinder head installed.......................................................................................................................................................................................................................................................................................................................................................................................... 5473
4.6.2 Renewing valve stem oil seals with cylinder head removed............................................................................................................................................................................................................................................................................................................................................................................................ 5477
5 Inlet and exhaust valves........................................................................................................................................................................................................................................................................................................................................................................................................................................ 5481
5.1 Valve dimensions.......................................................................................................................................................................................................................................................................................................................................................................................................................................... 5481
5.2 Checking valve guides..................................................................................................................................................................................................................................................................................................................................................................................................................................... 5481
5.3 Checking valves........................................................................................................................................................................................................................................................................................................................................................................................................................................... 5482
17 – Lubrication...................................................................................................................................................................................................................................................................................................................................................................................................................................................... 5483
1 Sump/oil pump................................................................................................................................................................................................................................................................................................................................................................................................................................................... 5483
1.1 Exploded view - sump/oil pump............................................................................................................................................................................................................................................................................................................................................................................................................................. 5483
1.2 Exploded view - sump (top section)........................................................................................................................................................................................................................................................................................................................................................................................................................ 5486
1.3 Engine oil................................................................................................................................................................................................................................................................................................................................................................................................................................................ 5487
1.4 Removing and installing sump (bottom section)............................................................................................................................................................................................................................................................................................................................................................................................................. 5487
1.5 Removing and installing sump (top section)................................................................................................................................................................................................................................................................................................................................................................................................................ 5489
1.6 Removing and installing oil pump.......................................................................................................................................................................................................................................................................................................................................................................................................................... 5493
1.7 Removing and installing oil level and oil temperature sender -G266-....................................................................................................................................................................................................................................................................................................................................................................................... 5494
1.8 Checking oil level........................................................................................................................................................................................................................................................................................................................................................................................................................................ 5495
2 Engine oil cooler............................................................................................................................................................................................................................................................................................................................................................................................................................................... 5496
2.1 Exploded view - engine oil cooler......................................................................................................................................................................................................................................................................................................................................................................................................................... 5496
2.2 Removing and installing engine oil cooler................................................................................................................................................................................................................................................................................................................................................................................................................. 5497
2.3 Removing and installing engine oil cooler (front)......................................................................................................................................................................................................................................................................................................................................................................................................... 5499
3 Crankcase breather.............................................................................................................................................................................................................................................................................................................................................................................................................................................. 5501
3.1 Removing and installing hose for crankcase breather system................................................................................................................................................................................................................................................................................................................................................................................................ 5501
4 Oil filter/oil pressure switches................................................................................................................................................................................................................................................................................................................................................................................................................................ 5502
4.1 Exploded view - oil filter housing/oil pressure switches.................................................................................................................................................................................................................................................................................................................................................................................................. 5502
4.2 Removing and installing oil temperature sender -G8-....................................................................................................................................................................................................................................................................................................................................................................................................... 5503
4.3 Checking oil pressure switch -F22-/oil pressure switch for reduced oil pressure -F378-.................................................................................................................................................................................................................................................................................................................................................................... 5504
4.4 Removing and installing oil pressure switch -F22-......................................................................................................................................................................................................................................................................................................................................................................................................... 5504
4.5 Removing and installing oil pressure switch for reduced oil pressure -F378-............................................................................................................................................................................................................................................................................................................................................................................... 5505
4.6 Removing and installing valve for oil pressure control -N428-............................................................................................................................................................................................................................................................................................................................................................................................. 5506
4.7 Checking oil pressure..................................................................................................................................................................................................................................................................................................................................................................................................................................... 5506
4.8 Removing and installing oil filter housing................................................................................................................................................................................................................................................................................................................................................................................................................ 5507
5 Oil circuit..................................................................................................................................................................................................................................................................................................................................................................................................................................................... 5509
5.1 Exploded view - oil spray jets/valves..................................................................................................................................................................................................................................................................................................................................................................................................................... 5509
5.2 Removing and installing oil spray jets/valves............................................................................................................................................................................................................................................................................................................................................................................................................. 5510
19 – Cooling.......................................................................................................................................................................................................................................................................................................................................................................................................................................................... 5512
1 Cooling system/coolant.......................................................................................................................................................................................................................................................................................................................................................................................................................................... 5512
1.1 Connection diagram - coolant hoses........................................................................................................................................................................................................................................................................................................................................................................................................................ 5512
1.2 Draining and filling cooling system....................................................................................................................................................................................................................................................................................................................................................................................................................... 5514
1.3 Checking cooling system for leaks......................................................................................................................................................................................................................................................................................................................................................................................................................... 5520
2 Coolant pump/thermostat assembly................................................................................................................................................................................................................................................................................................................................................................................................................................ 5523
2.1 Exploded view - coolant pump and thermostat............................................................................................................................................................................................................................................................................................................................................................................................................... 5523
2.2 Removing and installing electrical coolant pump........................................................................................................................................................................................................................................................................................................................................................................................................... 5524
2.2.1 Removing and installing continued coolant circulation pump -V51-.................................................................................................................................................................................................................................................................................................................................................................................... 5524
2.3 Thermostat opening values................................................................................................................................................................................................................................................................................................................................................................................................................................. 5526
2.4 Removing and installing coolant pump...................................................................................................................................................................................................................................................................................................................................................................................................................... 5526
2.5 Removing and installing coolant temperature sender -G62-.................................................................................................................................................................................................................................................................................................................................................................................................. 5528
2.6 Removing and installing map-controlled engine cooling system thermostat -F265-............................................................................................................................................................................................................................................................................................................................................................................ 5529
3 Coolant pipes................................................................................................................................................................................................................................................................................................................................................................................................................................................... 5531
3.1 Exploded view - coolant pipes............................................................................................................................................................................................................................................................................................................................................................................................................................. 5531
3.2 Removing and installing coolant pipes (front)............................................................................................................................................................................................................................................................................................................................................................................................................. 5532
3.3 Removing and installing coolant pipes (top front)......................................................................................................................................................................................................................................................................................................................................................................................................... 5532
3.4 Removing and installing coolant pipes (front centre)...................................................................................................................................................................................................................................................................................................................................................................................................... 5534
4 Radiator/radiator fans.......................................................................................................................................................................................................................................................................................................................................................................................................................................... 5536
4.1 Exploded view - radiator/radiator fans.................................................................................................................................................................................................................................................................................................................................................................................................................... 5536
4.2 Exploded view - radiator cowl and radiator fans........................................................................................................................................................................................................................................................................................................................................................................................................... 5538
4.3 Removing and installing radiator.......................................................................................................................................................................................................................................................................................................................................................................................................................... 5538
4.4 Removing and installing radiator fans..................................................................................................................................................................................................................................................................................................................................................................................................................... 5544
4.5 Removing and installing auxiliary radiator................................................................................................................................................................................................................................................................................................................................................................................................................ 5545
24 – Mixture preparation - injection.................................................................................................................................................................................................................................................................................................................................................................................................................................. 5547
1 Injection system................................................................................................................................................................................................................................................................................................................................................................................................................................................ 5547
1.1 Overview of fitting locations - injection system.......................................................................................................................................................................................................................................................................................................................................................................................................... 5547
1.2 Checking fuel system for leaks............................................................................................................................................................................................................................................................................................................................................................................................................................ 5553
1.3 Reducing pressure in high-pressure section of injection system............................................................................................................................................................................................................................................................................................................................................................................................ 5553
2 Vacuum system................................................................................................................................................................................................................................................................................................................................................................................................................................................... 5555
2.1 Exploded view - vacuum system............................................................................................................................................................................................................................................................................................................................................................................................................................. 5555
2.2 Checking vacuum system.................................................................................................................................................................................................................................................................................................................................................................................................................................... 5555
3 Injectors....................................................................................................................................................................................................................................................................................................................................................................................................................................................... 5557
3.1 Removing and installing injectors......................................................................................................................................................................................................................................................................................................................................................................................................................... 5557
3.2 Cleaning injectors........................................................................................................................................................................................................................................................................................................................................................................................................................................ 5561
4 Air cleaner..................................................................................................................................................................................................................................................................................................................................................................................................................................................... 5563
4.1 Exploded view - air cleaner housing....................................................................................................................................................................................................................................................................................................................................................................................................................... 5563
4.2 Removing and installing air cleaner housing............................................................................................................................................................................................................................................................................................................................................................................................................... 5564
4.3 Removing and installing air filter element................................................................................................................................................................................................................................................................................................................................................................................................................ 5566
5 Intake manifold................................................................................................................................................................................................................................................................................................................................................................................................................................................. 5567
5.1 Exploded view - intake manifold (top section)............................................................................................................................................................................................................................................................................................................................................................................................................. 5567
5.2 Exploded view - intake manifold (bottom section) with fuel rail........................................................................................................................................................................................................................................................................................................................................................................................... 5569
5.3 Removing and installing intake manifold (top section)..................................................................................................................................................................................................................................................................................................................................................................................................... 5571
5.4 Removing and installing intake manifold (bottom section) with fuel rail................................................................................................................................................................................................................................................................................................................................................................................... 5573
5.5 Removing and installing throttle valve module -J338- / -J544-............................................................................................................................................................................................................................................................................................................................................................................................. 5577
6 Senders and sensors............................................................................................................................................................................................................................................................................................................................................................................................................................................. 5578
6.1 Removing and installing fuel pressure sender -G247- / -G624-.............................................................................................................................................................................................................................................................................................................................................................................................. 5578
6.2 Checking fuel pressure and residual pressure (up to high-pressure pump)................................................................................................................................................................................................................................................................................................................................................................................... 5578
7 Engine control unit............................................................................................................................................................................................................................................................................................................................................................................................................................................. 5583
7.1 Removing and installing engine control unit -J623-........................................................................................................................................................................................................................................................................................................................................................................................................ 5583
7.2 Wiring and component check with isolator boxes -VAS 6606-................................................................................................................................................................................................................................................................................................................................................................................................. 5586
8 High-pressure pump.............................................................................................................................................................................................................................................................................................................................................................................................................................................. 5588
8.1 Exploded view - high-pressure pump........................................................................................................................................................................................................................................................................................................................................................................................................................ 5588
8.2 Removing and installing high-pressure pump................................................................................................................................................................................................................................................................................................................................................................................................................ 5589
8.3 Removing and installing high-pressure pipe................................................................................................................................................................................................................................................................................................................................................................................................................ 5592
9 Lambda probe.................................................................................................................................................................................................................................................................................................................................................................................................................................................... 5595
9.1 Exploded view - Lambda probe.............................................................................................................................................................................................................................................................................................................................................................................................................................. 5595
9.2 Removing and installing Lambda probe...................................................................................................................................................................................................................................................................................................................................................................................................................... 5595
26 – Exhaust system................................................................................................................................................................................................................................................................................................................................................................................................................................................... 5598
1 Exhaust pipes/silencers......................................................................................................................................................................................................................................................................................................................................................................................................................................... 5598
1.1 Exploded view - silencers................................................................................................................................................................................................................................................................................................................................................................................................................................. 5598
1.2 Separating exhaust pipes/silencers........................................................................................................................................................................................................................................................................................................................................................................................................................ 5600
1.3 Removing and installing front silencers................................................................................................................................................................................................................................................................................................................................................................................................................... 5601
1.4 Stress-free alignment of exhaust system................................................................................................................................................................................................................................................................................................................................................................................................................... 5603
1.5 Aligning tailpipes........................................................................................................................................................................................................................................................................................................................................................................................................................................ 5604
1.6 Checking exhaust system for leaks......................................................................................................................................................................................................................................................................................................................................................................................................................... 5604
1.7 Checking function of exhaust flap......................................................................................................................................................................................................................................................................................................................................................................................................................... 5605
2 Exhaust manifolds............................................................................................................................................................................................................................................................................................................................................................................................................................................... 5606
2.1 Exploded view - exhaust manifold.......................................................................................................................................................................................................................................................................................................................................................................................................................... 5606
2.2 Removing and installing exhaust manifolds................................................................................................................................................................................................................................................................................................................................................................................................................. 5607
3 Secondary air system............................................................................................................................................................................................................................................................................................................................................................................................................................................ 5611
3.1 Exploded view - secondary air system...................................................................................................................................................................................................................................................................................................................................................................................................................... 5611
3.2 Removing and installing secondary air pump -V101-/-V189-.................................................................................................................................................................................................................................................................................................................................................................................................. 5613
3.2.1 Removing and installing secondary air pump -V101-/-V189-, Audi RS 4/RS 5............................................................................................................................................................................................................................................................................................................................................................................ 5613
3.2.2 Removing and installing secondary air pump -V101-, Audi RS 5 Cabriolet.............................................................................................................................................................................................................................................................................................................................................................................. 5614
3.3 Removing and installing combination valve................................................................................................................................................................................................................................................................................................................................................................................................................. 5614
3.4 Checking combination valve for correct operation and leaks................................................................................................................................................................................................................................................................................................................................................................................................ 5615
3.5 Removing and installing senders for secondary air pressure -G609-/-G610-.................................................................................................................................................................................................................................................................................................................................................................................. 5617
28 – Ignition system.................................................................................................................................................................................................................................................................................................................................................................................................................................................. 5618
1 Ignition system................................................................................................................................................................................................................................................................................................................................................................................................................................................. 5618
1.1 Exploded view - ignition system........................................................................................................................................................................................................................................................................................................................................................................................................................... 5618
1.2 Test data, spark plugs.................................................................................................................................................................................................................................................................................................................................................................................................................................... 5619
1.3 Removing and installing ignition coils.................................................................................................................................................................................................................................................................................................................................................................................................................... 5619
1.4 Removing and installing knock sensor...................................................................................................................................................................................................................................................................................................................................................................................................................... 5621
1.4.1 Removing and installing knock sensors -G61- / -G66- / -G198- / -G199-............................................................................................................................................................................................................................................................................................................................................................................... 5621
1.5 Removing and installing Hall senders...................................................................................................................................................................................................................................................................................................................................................................................................................... 5622
1.5.1 Removing and installing Hall senders -G40- / -G163-................................................................................................................................................................................................................................................................................................................................................................................................. 5622
1.5.2 Removing and installing Hall senders -G300- / -G301-................................................................................................................................................................................................................................................................................................................................................................................................ 5622
1.6 Removing and installing engine speed sender -G28-......................................................................................................................................................................................................................................................................................................................................................................................................... 5623
8-speed_automatic_gearbox_0BK__four-wheel_drive........................................................................................................................................................................................................................................................................................................................................................................................................................... 5625
00 – Technical data................................................................................................................................................................................................................................................................................................................................................................................................................................................... 5629
1 Identification.................................................................................................................................................................................................................................................................................................................................................................................................................................................. 5629
1.1 Gearbox identification.................................................................................................................................................................................................................................................................................................................................................................................................................................... 5629
2 Safety precautions.............................................................................................................................................................................................................................................................................................................................................................................................................................................. 5630
2.1 Safety precautions when working on vehicle................................................................................................................................................................................................................................................................................................................................................................................................................ 5630
2.2 Safety precautions when using testers and measuring instruments during a road test........................................................................................................................................................................................................................................................................................................................................................................ 5631
2.3 Notes on tow-starting and towing.......................................................................................................................................................................................................................................................................................................................................................................................................................... 5631
3 Repair instructions............................................................................................................................................................................................................................................................................................................................................................................................................................................. 5632
3.1 Rules for cleanliness..................................................................................................................................................................................................................................................................................................................................................................................................................................... 5632
3.2 General notes............................................................................................................................................................................................................................................................................................................................................................................................................................................. 5632
3.3 General repair instructions............................................................................................................................................................................................................................................................................................................................................................................................................................... 5633
3.4 Contact corrosion......................................................................................................................................................................................................................................................................................................................................................................................................................................... 5635
4 Technical data.................................................................................................................................................................................................................................................................................................................................................................................................................................................. 5636
4.1 Allocation of gearbox to engine........................................................................................................................................................................................................................................................................................................................................................................................................................... 5636
4.2 Capacities................................................................................................................................................................................................................................................................................................................................................................................................................................................ 5637
5 Transmission layout............................................................................................................................................................................................................................................................................................................................................................................................................................................. 5639
5.1 Transmission layout - four-wheel drive.................................................................................................................................................................................................................................................................................................................................................................................................................... 5639
32 – Torque converter................................................................................................................................................................................................................................................................................................................................................................................................................................................. 5640
1 Torque converter................................................................................................................................................................................................................................................................................................................................................................................................................................................ 5640
1.1 Exploded view - torque converter.......................................................................................................................................................................................................................................................................................................................................................................................................................... 5640
1.2 Removing and installing torque converter.................................................................................................................................................................................................................................................................................................................................................................................................................. 5640
1.3 Draining torque converter................................................................................................................................................................................................................................................................................................................................................................................................................................. 5643
1.4 Checking torque converter................................................................................................................................................................................................................................................................................................................................................................................................................................. 5643
1.5 Removing and installing oil seal for torque converter..................................................................................................................................................................................................................................................................................................................................................................................................... 5643
37 – Controls, housing................................................................................................................................................................................................................................................................................................................................................................................................................................................ 5645
1 Selector mechanism.............................................................................................................................................................................................................................................................................................................................................................................................................................................. 5645
1.1 Exploded view - selector mechanism........................................................................................................................................................................................................................................................................................................................................................................................................................ 5645
1.2 Exploded view - selector lever handle..................................................................................................................................................................................................................................................................................................................................................................................................................... 5647
1.3 Exploded view - selector lever cable...................................................................................................................................................................................................................................................................................................................................................................................................................... 5648
1.4 Checking selector mechanism............................................................................................................................................................................................................................................................................................................................................................................................................................... 5649
1.5 Manual release from position P............................................................................................................................................................................................................................................................................................................................................................................................................................ 5651
1.6 Removing and installing selector mechanism................................................................................................................................................................................................................................................................................................................................................................................................................ 5652
1.7 Dismantling and assembling selector mechanism............................................................................................................................................................................................................................................................................................................................................................................................................. 5657
1.7.1 Removing and installing selector lever lock solenoid -N110-......................................................................................................................................................................................................................................................................................................................................................................................... 5657
1.7.2 Removing and installing selector lever sensors control unit -J587- and tiptronic switch -F189-...................................................................................................................................................................................................................................................................................................................................................... 5659
1.7.3 Removing and installing gear selector position P switch -F305-...................................................................................................................................................................................................................................................................................................................................................................................... 5660
1.8 Removing and installing selector lever handle............................................................................................................................................................................................................................................................................................................................................................................................................. 5660
1.9 Detaching selector lever boot from selector lever handle.................................................................................................................................................................................................................................................................................................................................................................................................. 5663
1.10 Removing and installing selector lever position display -Y26-............................................................................................................................................................................................................................................................................................................................................................................................ 5663
1.11 Removing and installing selector lever cable............................................................................................................................................................................................................................................................................................................................................................................................................. 5663
1.12 Checking and adjusting selector lever cable.............................................................................................................................................................................................................................................................................................................................................................................................................. 5668
1.13 Adjusting selector lever cable to basic setting.......................................................................................................................................................................................................................................................................................................................................................................................................... 5669
1.14 Renewing selector shaft oil seal......................................................................................................................................................................................................................................................................................................................................................................................................................... 5673
2 Removing and installing gearbox................................................................................................................................................................................................................................................................................................................................................................................................................................. 5676
2.1 Removing gearbox.......................................................................................................................................................................................................................................................................................................................................................................................................................................... 5676
2.2 Installing gearbox........................................................................................................................................................................................................................................................................................................................................................................................................................................ 5685
2.3 Tightening torques for gearbox............................................................................................................................................................................................................................................................................................................................................................................................................................ 5691
3 Assembly mountings.............................................................................................................................................................................................................................................................................................................................................................................................................................................. 5693
3.1 Exploded view - assembly mountings........................................................................................................................................................................................................................................................................................................................................................................................................................ 5693
3.2 Removing and installing tunnel cross member............................................................................................................................................................................................................................................................................................................................................................................................................... 5693
3.3 Removing and installing gearbox support with gearbox mounting............................................................................................................................................................................................................................................................................................................................................................................................. 5695
3.4 Removing and installing gearbox mounting.................................................................................................................................................................................................................................................................................................................................................................................................................. 5696
4 Transporting gearbox............................................................................................................................................................................................................................................................................................................................................................................................................................................ 5697
5 Securing to engine and gearbox support.......................................................................................................................................................................................................................................................................................................................................................................................................................... 5699
6 ATF............................................................................................................................................................................................................................................................................................................................................................................................................................................................. 5700
6.1 Exploded view - ATF drain and inspection plugs in gearbox................................................................................................................................................................................................................................................................................................................................................................................................. 5700
6.2 Checking ATF level........................................................................................................................................................................................................................................................................................................................................................................................................................................ 5700
6.3 Draining and filling ATF.................................................................................................................................................................................................................................................................................................................................................................................................................................. 5704
7 ATF circuit..................................................................................................................................................................................................................................................................................................................................................................................................................................................... 5709
7.1 Exploded view - ATF circuit............................................................................................................................................................................................................................................................................................................................................................................................................................... 5709
7.2 Removing and installing ATF filter........................................................................................................................................................................................................................................................................................................................................................................................................................ 5711
7.3 Cleaning ATF lines........................................................................................................................................................................................................................................................................................................................................................................................................................................ 5712
7.4 Removing and installing ATF lines......................................................................................................................................................................................................................................................................................................................................................................................................................... 5713
38 – Gears, control................................................................................................................................................................................................................................................................................................................................................................................................................................................... 5716
1 ATF system...................................................................................................................................................................................................................................................................................................................................................................................................................................................... 5716
1.1 Exploded view - ATF system................................................................................................................................................................................................................................................................................................................................................................................................................................ 5716
1.2 Removing and installing oil pan........................................................................................................................................................................................................................................................................................................................................................................................................................... 5718
2 Mechatronic unit................................................................................................................................................................................................................................................................................................................................................................................................................................................ 5723
2.1 Removing and installing mechatronic unit.................................................................................................................................................................................................................................................................................................................................................................................................................. 5723
39 – Final drive - front differential................................................................................................................................................................................................................................................................................................................................................................................................................................. 5728
1 Final drive..................................................................................................................................................................................................................................................................................................................................................................................................................................................... 5728
1.1 Exploded view - final drive............................................................................................................................................................................................................................................................................................................................................................................................................................... 5728
1.2 Renewing O-ring on cover for front final drive............................................................................................................................................................................................................................................................................................................................................................................................................ 5730
2 Gear oil........................................................................................................................................................................................................................................................................................................................................................................................................................................................ 5732
2.1 Exploded view - gear oil drain and inspection plugs....................................................................................................................................................................................................................................................................................................................................................................................................... 5732
2.2 Checking gear oil level................................................................................................................................................................................................................................................................................................................................................................................................................................... 5732
2.2.1 Checking gear oil level, front final drive.......................................................................................................................................................................................................................................................................................................................................................................................................... 5732
2.2.2 Checking gear oil level, transfer box............................................................................................................................................................................................................................................................................................................................................................................................................... 5734
2.3 Draining and filling gear oil............................................................................................................................................................................................................................................................................................................................................................................................................................. 5736
2.3.1 Draining and filling gear oil, front final drive.................................................................................................................................................................................................................................................................................................................................................................................................... 5736
2.3.2 Draining and filling gear oil, transfer box......................................................................................................................................................................................................................................................................................................................................................................................................... 5739
3 Oil seals....................................................................................................................................................................................................................................................................................................................................................................................................................................................... 5743
3.1 Renewing oil seal (left-side)............................................................................................................................................................................................................................................................................................................................................................................................................................. 5743
3.2 Renewing oil seal (right-side)............................................................................................................................................................................................................................................................................................................................................................................................................................ 5746
4 Differential.................................................................................................................................................................................................................................................................................................................................................................................................................................................... 5748
4.1 Removing and installing flange shaft (left-side).......................................................................................................................................................................................................................................................................................................................................................................................................... 5748
4.2 Removing and installing flange shaft (right-side)......................................................................................................................................................................................................................................................................................................................................................................................................... 5749
5 Centre differential............................................................................................................................................................................................................................................................................................................................................................................................................................................. 5753
5.1 Exploded view - centre differential....................................................................................................................................................................................................................................................................................................................................................................................................................... 5753
5.2 Removing and installing centre differential............................................................................................................................................................................................................................................................................................................................................................................................................... 5754
5.3 Renewing oil seal for rear splined shaft.................................................................................................................................................................................................................................................................................................................................................................................................................. 5759
5.3.1 Renewing oil seal for rear splined shaft, vehicles with rear splined shaft without vibration damper................................................................................................................................................................................................................................................................................................................................................. 5759
5.3.2 Renewing oil seal for rear splined shaft, vehicles with rear splined shaft and vibration damper..................................................................................................................................................................................................................................................................................................................................................... 5761
5.4 Removing and installing rear splined shaft................................................................................................................................................................................................................................................................................................................................................................................................................ 5764
5.5 Renewing ball bearing for rear splined shaft.............................................................................................................................................................................................................................................................................................................................................................................................................. 5767
5.6 Renewing ball bearing for centre differential............................................................................................................................................................................................................................................................................................................................................................................................................. 5768
6 Gearbox control system.......................................................................................................................................................................................................................................................................................................................................................................................................................................... 5771
6.1 Overview of fitting locations - gearbox control system.................................................................................................................................................................................................................................................................................................................................................................................................... 5771
Air_conditioner_with_refrigerant_R134a.................................................................................................................................................................................................................................................................................................................................................................................................................................... 5774
87 – Air conditioning system.......................................................................................................................................................................................................................................................................................................................................................................................................................................... 5780
1 Warning instructions when working on vehicles with high-voltage system.......................................................................................................................................................................................................................................................................................................................................................................................... 5780
1.1 Working on vehicles with high-voltage system (hybrid vehicles)............................................................................................................................................................................................................................................................................................................................................................................................ 5780
1.2 Visual inspection of high-voltage components and wiring for damage........................................................................................................................................................................................................................................................................................................................................................................................ 5781
2 General information on air conditioning systems................................................................................................................................................................................................................................................................................................................................................................................................................. 5783
2.1 General notes............................................................................................................................................................................................................................................................................................................................................................................................................................................. 5783
2.2 Introduction.............................................................................................................................................................................................................................................................................................................................................................................................................................................. 5783
2.3 Safety measures for vehicles with start/stop system....................................................................................................................................................................................................................................................................................................................................................................................................... 5785
2.4 Other reference material.................................................................................................................................................................................................................................................................................................................................................................................................................................. 5785
2.5 Principles of air conditioning systems.................................................................................................................................................................................................................................................................................................................................................................................................................... 5786
2.5.1 Physical principles................................................................................................................................................................................................................................................................................................................................................................................................................................. 5786
2.5.2 Pressure and boiling point.......................................................................................................................................................................................................................................................................................................................................................................................................................... 5786
2.5.3 Vapour pressure table for refrigerant R134a......................................................................................................................................................................................................................................................................................................................................................................................................... 5787
2.6 Refrigerant R134a......................................................................................................................................................................................................................................................................................................................................................................................................................................... 5788
2.6.1 Physical properties of refrigerant R134a............................................................................................................................................................................................................................................................................................................................................................................................................ 5789
2.6.2 Critical point...................................................................................................................................................................................................................................................................................................................................................................................................................................... 5789
2.6.3 Environmental aspects of refrigerant R134a.......................................................................................................................................................................................................................................................................................................................................................................................................... 5789
2.7 Properties of refrigerant R134a........................................................................................................................................................................................................................................................................................................................................................................................................................... 5790
2.7.1 Trade names and designations........................................................................................................................................................................................................................................................................................................................................................................................................................ 5790
2.7.2 Colour.............................................................................................................................................................................................................................................................................................................................................................................................................................................. 5790
2.7.3 Vapour pressure..................................................................................................................................................................................................................................................................................................................................................................................................................................... 5790
2.7.4 Physical properties of R134a........................................................................................................................................................................................................................................................................................................................................................................................................................ 5790
2.7.5 Reaction with metals................................................................................................................................................................................................................................................................................................................................................................................................................................ 5791
2.7.6 Critical temperature/critical pressure.............................................................................................................................................................................................................................................................................................................................................................................................................. 5791
2.7.7 Water content....................................................................................................................................................................................................................................................................................................................................................................................................................................... 5791
2.7.8 Combustibility...................................................................................................................................................................................................................................................................................................................................................................................................................................... 5791
2.7.9 Charge factor....................................................................................................................................................................................................................................................................................................................................................................................................................................... 5791
2.7.10 Tracing leaks...................................................................................................................................................................................................................................................................................................................................................................................................................................... 5791
2.8 Refrigerant oil........................................................................................................................................................................................................................................................................................................................................................................................................................................... 5792
2.8.1 Properties of refrigerant oil....................................................................................................................................................................................................................................................................................................................................................................................................................... 5792
2.9 How air conditioning works................................................................................................................................................................................................................................................................................................................................................................................................................................ 5793
2.9.1 Comfort of vehicle occupants........................................................................................................................................................................................................................................................................................................................................................................................................................ 5794
2.9.2 Environmental aspects............................................................................................................................................................................................................................................................................................................................................................................................................................... 5794
2.10 General work safety...................................................................................................................................................................................................................................................................................................................................................................................................................................... 5794
2.11 Product properties....................................................................................................................................................................................................................................................................................................................................................................................................................................... 5795
2.12 Handling refrigerant..................................................................................................................................................................................................................................................................................................................................................................................................................................... 5795
2.13 Handling pressure vessels................................................................................................................................................................................................................................................................................................................................................................................................................................ 5796
2.14 Safety regulations for working with extraction and charging systems...................................................................................................................................................................................................................................................................................................................................................................................... 5797
2.15 Safety measures for working on vehicles with air conditioning system and for handling refrigerant R134a.................................................................................................................................................................................................................................................................................................................................................. 5797
2.16 Basic rules for working on refrigerant circuit........................................................................................................................................................................................................................................................................................................................................................................................................... 5801
2.16.1 General notes...................................................................................................................................................................................................................................................................................................................................................................................................................................... 5803
2.16.2 Cleaning refrigerant circuit....................................................................................................................................................................................................................................................................................................................................................................................................................... 5803
2.16.3 Additionally for vehicles with air conditioner compressor without magnetic clutch (with air conditioner compressor regulating valve -N280- only)................................................................................................................................................................................................................................................................................................... 5804
2.16.4 Additional information on vehicles with high-voltage system........................................................................................................................................................................................................................................................................................................................................................................................ 5804
2.16.5 O-rings............................................................................................................................................................................................................................................................................................................................................................................................................................................ 5806
2.17 Before using air conditioner after system has been re-charged............................................................................................................................................................................................................................................................................................................................................................................................ 5806
3 General information on refrigerant circuit...................................................................................................................................................................................................................................................................................................................................................................................................................... 5807
3.1 Components of refrigerant circuit......................................................................................................................................................................................................................................................................................................................................................................................................................... 5808
3.2 Layout of components of refrigerant circuit and their influence on high-pressure and low-pressure sides................................................................................................................................................................................................................................................................................................................................................... 5809
3.2.1 Mechanically driven air conditioner compressor...................................................................................................................................................................................................................................................................................................................................................................................................... 5810
3.2.2 Electrically driven air conditioner compressor for vehicles with a high-voltage system.............................................................................................................................................................................................................................................................................................................................................................. 5811
3.2.3 Condenser........................................................................................................................................................................................................................................................................................................................................................................................................................................... 5815
3.2.4 Evaporator.......................................................................................................................................................................................................................................................................................................................................................................................................................................... 5815
3.2.5 Heat exchanger for heat pump operation.............................................................................................................................................................................................................................................................................................................................................................................................................. 5816
3.2.6 Fluid collector..................................................................................................................................................................................................................................................................................................................................................................................................................................... 5816
3.2.7 Reservoir........................................................................................................................................................................................................................................................................................................................................................................................................................................... 5817
3.2.8 Restrictor.......................................................................................................................................................................................................................................................................................................................................................................................................................................... 5817
3.2.9 Receiver............................................................................................................................................................................................................................................................................................................................................................................................................................................ 5819
3.2.10 Expansion valve.................................................................................................................................................................................................................................................................................................................................................................................................................................... 5820
3.2.11 Expansion valve with shut-off valve................................................................................................................................................................................................................................................................................................................................................................................................................ 5820
3.2.12 Shut-off valves for refrigerant.................................................................................................................................................................................................................................................................................................................................................................................................................... 5821
3.2.13 Refrigerant line with internal heat exchanger...................................................................................................................................................................................................................................................................................................................................................................................................... 5823
3.2.14 Quick-release couplings on refrigerant line........................................................................................................................................................................................................................................................................................................................................................................................................ 5823
3.2.15 O-rings............................................................................................................................................................................................................................................................................................................................................................................................................................................ 5825
3.2.16 Pipes and hoses of refrigerant circuit............................................................................................................................................................................................................................................................................................................................................................................................................. 5825
3.2.17 High-pressure safety valve......................................................................................................................................................................................................................................................................................................................................................................................................................... 5825
3.2.18 Non-return valves.................................................................................................................................................................................................................................................................................................................................................................................................................................. 5826
3.3 Design of refrigerant circuit............................................................................................................................................................................................................................................................................................................................................................................................................................. 5827
3.3.1 Refrigerant circuit with expansion valve and evaporator............................................................................................................................................................................................................................................................................................................................................................................................. 5827
3.3.2 Refrigerant circuit with restrictor and reservoir................................................................................................................................................................................................................................................................................................................................................................................................... 5827
3.4 Refrigerant circuit with electrically driven air conditioner compressor................................................................................................................................................................................................................................................................................................................................................................................... 5828
3.5 Connections for quick-release coupling in refrigerant circuit............................................................................................................................................................................................................................................................................................................................................................................................. 5830
3.5.2 Connections with primary sealing valve (ball valve)................................................................................................................................................................................................................................................................................................................................................................................................. 5831
3.5.3 Differences in service connections depending on refrigerant (R134a or R1234yf)...................................................................................................................................................................................................................................................................................................................................................................... 5834
3.6 Switches and senders in refrigerant circuit and related connections....................................................................................................................................................................................................................................................................................................................................................................................... 5837
3.6.4 Connections with valve for refrigerant circuit switches............................................................................................................................................................................................................................................................................................................................................................................................. 5839
3.6.5 Air conditioning system pressure switch -F129-...................................................................................................................................................................................................................................................................................................................................................................................................... 5839
3.6.7 Refrigerant pressure and temperature sender......................................................................................................................................................................................................................................................................................................................................................................................................... 5841
3.6.8 Air conditioner compressor regulating valve -N280-.................................................................................................................................................................................................................................................................................................................................................................................................. 5844
3.7 Electrical components not installed in refrigerant circuit................................................................................................................................................................................................................................................................................................................................................................................................ 5845
3.7.1 Radiator fan control unit -J293-.................................................................................................................................................................................................................................................................................................................................................................................................................... 5845
3.8 Pressures and temperatures in refrigerant circuit......................................................................................................................................................................................................................................................................................................................................................................................................... 5845
3.8.1 Refrigerant circuit with expansion valve............................................................................................................................................................................................................................................................................................................................................................................................................ 5846
3.8.2 Refrigerant circuit with restrictor and reservoir................................................................................................................................................................................................................................................................................................................................................................................................... 5848
3.9 Tests and measurements performed with pressure gauge...................................................................................................................................................................................................................................................................................................................................................................................................... 5850
3.9.1 Pressure gauges permit the following test and measurement operations................................................................................................................................................................................................................................................................................................................................................................................ 5850
3.10 Air conditioner service and recycling units.............................................................................................................................................................................................................................................................................................................................................................................................................. 5851
3.10.1 Classification of extraction systems............................................................................................................................................................................................................................................................................................................................................................................................................... 5851
3.10.2 Charging systems that do not require a permit...................................................................................................................................................................................................................................................................................................................................................................................................... 5852
3.11 Repair notes for refrigerant circuit..................................................................................................................................................................................................................................................................................................................................................................................................................... 5852
4 Laws and regulations............................................................................................................................................................................................................................................................................................................................................................................................................................................ 5853
4.1 Laws and regulations...................................................................................................................................................................................................................................................................................................................................................................................................................................... 5853
4.1.1 Change-over of an R12 refrigerant circuit to an R134a refrigerant circuit and servicing (retrofit).................................................................................................................................................................................................................................................................................................................................................. 5857
4.1.2 Keeping refrigerant records......................................................................................................................................................................................................................................................................................................................................................................................................................... 5857
5 Refrigerant circuit............................................................................................................................................................................................................................................................................................................................................................................................................................................. 5858
5.1 Important repair notes for air conditioning systems....................................................................................................................................................................................................................................................................................................................................................................................................... 5858
5.2 Converting refrigerant circuits from refrigerant R12 to refrigerant R134a................................................................................................................................................................................................................................................................................................................................................................................. 5858
5.3 Working with the air conditioner service station.......................................................................................................................................................................................................................................................................................................................................................................................................... 5859
5.3.1 Important notes for working with the air conditioner service station................................................................................................................................................................................................................................................................................................................................................................................ 5862
5.3.2 Connecting air conditioner service station for measuring and testing................................................................................................................................................................................................................................................................................................................................................................................ 5863
5.3.3 Discharging refrigerant circuit with air conditioner service station................................................................................................................................................................................................................................................................................................................................................................................ 5864
5.3.4 Evacuating refrigerant circuit with air conditioner service station................................................................................................................................................................................................................................................................................................................................................................................. 5866
5.3.5 Charging refrigerant circuit with air conditioner service station................................................................................................................................................................................................................................................................................................................................................................................... 5871
5.3.6 Starting up air conditioner after charging.......................................................................................................................................................................................................................................................................................................................................................................................................... 5872
5.3.7 Pouring refrigerant into reservoir (charging cylinder or storage vessel) of air conditioner service station......................................................................................................................................................................................................................................................................................................................................... 5874
5.3.8 Discharging air conditioner service station......................................................................................................................................................................................................................................................................................................................................................................................................... 5874
5.4 Blowing out refrigerant circuit with compressed air and nitrogen.......................................................................................................................................................................................................................................................................................................................................................................................... 5875
5.4.1 Blowing out refrigerant circuit..................................................................................................................................................................................................................................................................................................................................................................................................................... 5879
5.5 Cleaning (flushing) refrigerant circuit with refrigerant R134a............................................................................................................................................................................................................................................................................................................................................................................................ 5880
5.5.1 Block diagrams for various flushing circuits........................................................................................................................................................................................................................................................................................................................................................................................................ 5891
5.5.2 Flushing electrically driven air conditioner compressor (removing refrigerant oil).................................................................................................................................................................................................................................................................................................................................................................. 5899
5.5.3 Adapters for connecting flushing circuits........................................................................................................................................................................................................................................................................................................................................................................................................... 5905
5.6 Tracing leaks in refrigerant circuit...................................................................................................................................................................................................................................................................................................................................................................................................................... 5944
5.6.1 Tracing leaks in refrigerant circuit using electronic leak detector (e.g. V.A.G 1796)............................................................................................................................................................................................................................................................................................................................................................... 5947
5.6.2 Tracing leaks in refrigerant circuit with leak detection system VAS 6201............................................................................................................................................................................................................................................................................................................................................................................ 5948
5.6.3 Establishing leaks by way of vacuum test with air conditioner service station or nitrogen pressure test............................................................................................................................................................................................................................................................................................................................................. 5958
6 Problems with refrigerant circuit............................................................................................................................................................................................................................................................................................................................................................................................................................... 5960
6.1 Possible complaints about refrigerant circuit............................................................................................................................................................................................................................................................................................................................................................................................................. 5960
6.1.1 Test requirements................................................................................................................................................................................................................................................................................................................................................................................................................................... 5960
6.1.2 Possible complaints................................................................................................................................................................................................................................................................................................................................................................................................................................. 5960
7 Connecting air conditioner service station ..................................................................................................................................................................................................................................................................................................................................................................................................................... 5962
7.1 Connecting air conditioner service station - vehicles with a connection on the low-pressure and high-pressure side of the refrigerant circuit............................................................................................................................................................................................................................................................................................................. 5964
7.2 Connecting air conditioner service station - vehicles with no connection on the low-pressure side of the refrigerant circuit.............................................................................................................................................................................................................................................................................................................................. 5965
7.2.3 Connecting air conditioner service station for measuring and testing................................................................................................................................................................................................................................................................................................................................................................................ 5967
8 Checking pressures.............................................................................................................................................................................................................................................................................................................................................................................................................................................. 5968
8.1 Checking pressures in refrigerant circuit with air conditioner service station (with ignition switched off)............................................................................................................................................................................................................................................................................................................................................... 5970
8.1.1 Test requirements................................................................................................................................................................................................................................................................................................................................................................................................................................... 5971
8.1.2 Checking pressures.................................................................................................................................................................................................................................................................................................................................................................................................................................. 5973
8.2 Checking pressures on vehicles with a restrictor and reservoir (with internally regulated air conditioner compressor)..................................................................................................................................................................................................................................................................................................................................... 5976
8.2.1 Specifications for pressures in refrigerant circuit................................................................................................................................................................................................................................................................................................................................................................................................. 5977
8.3 Checking pressures on vehicles with an expansion valve and receiver (with internally regulated air conditioner compressor)................................................................................................................................................................................................................................................................................................................................ 5980
8.3.1 Specifications for pressures in refrigerant circuit................................................................................................................................................................................................................................................................................................................................................................................................. 5981
8.4 Checking pressures on vehicles with restrictor, reservoir and air conditioner compressor regulating valve -N280- (with externally regulated air conditioner compressor)................................................................................................................................................................................................................................................................................... 5986
8.4.1 Specifications for pressures in refrigerant circuit................................................................................................................................................................................................................................................................................................................................................................................................. 5987
8.5 Checking pressures on vehicles with expansion valve, receiver and air conditioner compressor regulating valve -N280- (with externally regulated air conditioner compressor)............................................................................................................................................................................................................................................................................... 5994
8.5.1 Specifications for pressures in refrigerant circuit................................................................................................................................................................................................................................................................................................................................................................................................. 5995
8.6 Checking pressures on vehicles with an electrically driven air conditioner compressor (vehicles with a high-voltage system)............................................................................................................................................................................................................................................................................................................................... 6006
8.6.1 Specifications for pressures in refrigerant circuit on vehicles without heat pump................................................................................................................................................................................................................................................................................................................................................................... 6010
8.6.2 Specifications for pressures in refrigerant circuit on vehicles with heat pump...................................................................................................................................................................................................................................................................................................................................................................... 6030
9 Renewing components of refrigerant circuit...................................................................................................................................................................................................................................................................................................................................................................................................................... 6048
9.1 Renewing components....................................................................................................................................................................................................................................................................................................................................................................................................................................... 6048
9.1.1 Leaking or damaged components (except air conditioner compressor, reservoir or receiver)............................................................................................................................................................................................................................................................................................................................................................ 6051
9.1.2 Leaking or damaged components (except air conditioner compressor, reservoir or receiver)............................................................................................................................................................................................................................................................................................................................................................ 6052
9.1.3 Renewing air conditioner compressor without the need for refrigerant circuit cleaning............................................................................................................................................................................................................................................................................................................................................................... 6053
9.1.4 Renewing air conditioner compressor on account of leakage or internal damage........................................................................................................................................................................................................................................................................................................................................................................ 6056
9.1.5 Renewing receiver or reservoir and restrictor after cleaning refrigerant circuit.................................................................................................................................................................................................................................................................................................................................................................... 6059
9.1.6 Renewing receiver or reservoir without the need for refrigerant circuit cleaning.................................................................................................................................................................................................................................................................................................................................................................... 6060
9.1.7 Renewing desiccant cartridge/desiccant bag without the need for refrigerant circuit cleaning........................................................................................................................................................................................................................................................................................................................................................ 6061
9.1.8 Removing/installing and renewing air conditioner compressor regulating valve -N280-................................................................................................................................................................................................................................................................................................................................................................. 6061
10 Capacities for refrigerant R134a/refrigerant oil and approved refrigerant oils................................................................................................................................................................................................................................................................................................................................................................................. 6068
10.1 Capacities for refrigerant R134a......................................................................................................................................................................................................................................................................................................................................................................................................................... 6068
10.1.1 Capacities for Audi A1 (8X_) 2011 ►................................................................................................................................................................................................................................................................................................................................................................................................................ 6069
10.1.2 Capacities for Audi A2 (8Z_) 2001 ►................................................................................................................................................................................................................................................................................................................................................................................................................ 6070
10.1.3 Capacities for Audi A3 (8L_) 1997 ► and Audi TT (8N_) 1999 ►....................................................................................................................................................................................................................................................................................................................................................................................... 6071
10.1.4 Capacities for Audi A3 (8P_) 2004 ►, Audi Q3 (8U_ or 84_ for China) 2012 ►......................................................................................................................................................................................................................................................................................................................................................................... 6074
10.1.5 Capacities for Audi A3 (8V_ or 85_ for China) 2013 ►, Audi A3 e-tron (8V_ ) 2015 ►, Audi RS 3 (8V_) 2016 ►......................................................................................................................................................................................................................................................................................................................................... 6075
10.1.6 Capacities for Audi TT (8J_) 2007 ►................................................................................................................................................................................................................................................................................................................................................................................................................ 6076
10.1.7 Capacities for Audi TT (FV_) 2015 ►................................................................................................................................................................................................................................................................................................................................................................................................................ 6077
10.1.8 Capacities for Audi 80 (8A_ / 8C_), Audi Coupé (8B_), Audi Cabriolet (8G_) ► 2002.................................................................................................................................................................................................................................................................................................................................................................. 6078
10.1.9 Capacities for Audi A4 (8D_) 1995 ►................................................................................................................................................................................................................................................................................................................................................................................................................ 6078
10.1.10 Capacities for Audi A4 (8E_) 2001 ►, Audi A4 Cabriolet (8H_) 2003 ►............................................................................................................................................................................................................................................................................................................................................................................... 6080
10.1.11 Capacities for Audi A4 (8K_) 2008 ►, Audi A5 Coupé and Sportback (8T_) 2008 ►, Audi Q5 (8R_ or 83_ for China) 2008 ►, Audi A5 Cabriolet (8F_) 2009 ►, Audi Q5 hybrid (8R_) 2011 ►................................................................................................................................................................................................................................................................. 6082
10.1.12 Capacities for Audi A4 (8W_) ► 2016............................................................................................................................................................................................................................................................................................................................................................................................................... 6093
10.1.13 Capacities for Audi 100 / Audi A6 (4A_) ► 1998.................................................................................................................................................................................................................................................................................................................................................................................................... 6093
10.1.14 Capacities for Audi A6 (4B_) 1998 ► and Audi allroad (4B_) ► 2005................................................................................................................................................................................................................................................................................................................................................................................. 6094
10.1.15 Capacities for Audi A6 (4F_) 2005 ►............................................................................................................................................................................................................................................................................................................................................................................................................... 6099
10.1.16 Capacities for Audi A6 (4G_ or 4X_ for China ) 2011 ►, Audi A7 (4G_ or 4X_ for China) 2011 ►, Audi A6 hybrid (4G_) 012 ►, A6 e-tron (4G_) 2017 ►................................................................................................................................................................................................................................................................................................. 6100
10.1.17 Capacities for Audi V8 (4C_) ► 1994............................................................................................................................................................................................................................................................................................................................................................................................................... 6102
10.1.18 Capacities for Audi A8 (4D_) 1994 ►............................................................................................................................................................................................................................................................................................................................................................................................................... 6103
10.1.19 Capacities for Audi A8 (4E_) 2003 ►............................................................................................................................................................................................................................................................................................................................................................................................................... 6104
10.1.20 Capacities for Audi A8 (4H_) 2010 ►, Audi A8 hybrid (4H_) 2012 ►.................................................................................................................................................................................................................................................................................................................................................................................. 6105
10.1.21 Capacities for Audi Q7 (4L_) 2006 ►, Audi Q7 (4M_) 2016 ►......................................................................................................................................................................................................................................................................................................................................................................................... 6106
10.1.22 Capacities for Audi R8 (42_) 2008 ►, Audi R8 (4S_) 2015 ►......................................................................................................................................................................................................................................................................................................................................................................................... 6108
10.2 Approved refrigerant oils and refrigerant oil capacities................................................................................................................................................................................................................................................................................................................................................................................................. 6109
10.2.1 Approved refrigerant oils.......................................................................................................................................................................................................................................................................................................................................................................................................................... 6110
10.2.2 Refrigerant oil capacities......................................................................................................................................................................................................................................................................................................................................................................................................................... 6112
10.2.3 Capacities for Audi A1 (8X_) 2011 ►................................................................................................................................................................................................................................................................................................................................................................................................................ 6113
10.2.4 Capacities for Audi A2 (8Z_) 2001 ►................................................................................................................................................................................................................................................................................................................................................................................................................ 6116
10.2.5 Capacities for Audi A3 (8L_) 1997 ► and Audi TT (8N_) 1999 ►....................................................................................................................................................................................................................................................................................................................................................................................... 6116
10.2.6 Capacities for Audi A3 (8P_) 2004 ►, Audi Q3 (8U_ or 84_ for China) 2012 ►......................................................................................................................................................................................................................................................................................................................................................................... 6117
10.2.7 Capacities for Audi A3 (8V_ or 85_ for China) 2013 ►, Audi A3 e-tron (8V_ ) 2015 ►, Audi RS 3 (8V_) 2016 ►......................................................................................................................................................................................................................................................................................................................................... 6119
10.2.8 Capacities for Audi TT (8J_) 2007 ►................................................................................................................................................................................................................................................................................................................................................................................................................ 6121
10.2.9 Capacities for Audi TT (FV_) 2015 ►................................................................................................................................................................................................................................................................................................................................................................................................................ 6123
10.2.10 Capacities for Audi 80 (8A_/8C_), Audi Coupé (8B_), Audi Cabriolet (8G_) ► 2002................................................................................................................................................................................................................................................................................................................................................................... 6124
10.2.11 Capacities for Audi A4 (8D_) 1995 ►............................................................................................................................................................................................................................................................................................................................................................................................................... 6125
10.2.12 Capacities for Audi A4 (8E_) 2001 ►, Audi A4 Cabriolet (8H_) 2003 ►............................................................................................................................................................................................................................................................................................................................................................................... 6125
10.2.13 Capacities for Audi A4 (8K_) 2008 ►, Audi A5 Coupé and Sportback (8T_) 2008 ►, Audi Q5 (8R_ or 83_ for China) 2008 ►, Audi A5 Cabriolet (8F_) 2009 ►, Audi Q5 hybrid (8R_) 2011 ►................................................................................................................................................................................................................................................................. 6127
10.2.14 Capacities for Audi A4 (8W_) ► 2016............................................................................................................................................................................................................................................................................................................................................................................................................... 6133
10.2.15 Capacities for Audi 100 / Audi A6 (4A_) ► 1998.................................................................................................................................................................................................................................................................................................................................................................................................... 6133
10.2.16 Capacities for Audi A6 (4B_) 1998 ► and Audi allroad ► 2005....................................................................................................................................................................................................................................................................................................................................................................................... 6134
10.2.17 Capacities for Audi A6 (4F_) 2005 ►............................................................................................................................................................................................................................................................................................................................................................................................................... 6136
10.2.18 Capacities for Audi A6 (4G_ or 4X_ for China ) 2011 ►, Audi A7 (4G_ or 4X_ for China) 2011 ►, Audi A6 hybrid (4G_) 012 ►, A6 e-tron (4G_) 2017 ►................................................................................................................................................................................................................................................................................................. 6137
10.2.19 Capacities for Audi V8 (4C_) ► 1994............................................................................................................................................................................................................................................................................................................................................................................................................... 6140
10.2.20 Capacities for Audi A8 (4D_) 1994 ►............................................................................................................................................................................................................................................................................................................................................................................................................... 6140
10.2.21 Capacities for Audi A8 (4E_) 2003 ►............................................................................................................................................................................................................................................................................................................................................................................................................... 6141
10.2.22 Capacities for Audi A8 (4H_) 2010 ►, Audi A8 hybrid (4H_) 2012 ►.................................................................................................................................................................................................................................................................................................................................................................................. 6142
10.2.23 Capacities for Audi Q7 (4L_) 2006 ►, Audi Q7 (4M_) 2016 ►......................................................................................................................................................................................................................................................................................................................................................................................... 6146
10.2.24 Capacities for Audi R8 (42_) 2008 ►, Audi R8 (4S_) 2015 ►......................................................................................................................................................................................................................................................................................................................................................................................... 6150
11 Test equipment and tools....................................................................................................................................................................................................................................................................................................................................................................................................................................... 6153
11.1 List of testers, tools and materials..................................................................................................................................................................................................................................................................................................................................................................................................................... 6153
11.1.1 Tools and materials available from regional sales centre or importer............................................................................................................................................................................................................................................................................................................................................................................... 6153
11.1.2 Commercially available tools and materials......................................................................................................................................................................................................................................................................................................................................................................................................... 6154
11.1.3 Improvised tools................................................................................................................................................................................................................................................................................................................................................................................................................................... 6155
11.2 Tools and materials available from regional sales centre or importer..................................................................................................................................................................................................................................................................................................................................................................................... 6155
11.3 Commercially available tools and materials............................................................................................................................................................................................................................................................................................................................................................................................................... 6158
11.4 Improvised tools......................................................................................................................................................................................................................................................................................................................................................................................................................................... 6159
Air_conditioners_with_refrigerant_R1234yf_-_General_information........................................................................................................................................................................................................................................................................................................................................................................................................... 6160
00 – Technical data................................................................................................................................................................................................................................................................................................................................................................................................................................................... 6164
1 Safety precautions.............................................................................................................................................................................................................................................................................................................................................................................................................................................. 6164
1.1 Safety precautions when working on air conditioners....................................................................................................................................................................................................................................................................................................................................................................................................... 6164
1.2 Safety precautions when handling refrigerants............................................................................................................................................................................................................................................................................................................................................................................................................. 6164
1.3 Safety precautions for working on vehicles with start/stop system......................................................................................................................................................................................................................................................................................................................................................................................... 6165
1.4 Safety precautions for handling air conditioner service stations.......................................................................................................................................................................................................................................................................................................................................................................................... 6165
1.5 Safety precautions when working on vehicles with high-voltage system...................................................................................................................................................................................................................................................................................................................................................................................... 6166
1.6 Safety precautions when working in the vicinity of high-voltage components................................................................................................................................................................................................................................................................................................................................................................................ 6167
1.7 Safety precautions when handling pressure vessels......................................................................................................................................................................................................................................................................................................................................................................................................... 6167
2 Laws and regulations............................................................................................................................................................................................................................................................................................................................................................................................................................................ 6168
2.1 Legal stipulations and directives......................................................................................................................................................................................................................................................................................................................................................................................................................... 6168
2.2 Charging the refrigerant circuit with other refrigerants.................................................................................................................................................................................................................................................................................................................................................................................................. 6169
2.3 Occupational Health & Safety.............................................................................................................................................................................................................................................................................................................................................................................................................................. 6169
3 Repair instructions............................................................................................................................................................................................................................................................................................................................................................................................................................................. 6171
3.1 Rules on cleanliness...................................................................................................................................................................................................................................................................................................................................................................................................................................... 6171
3.2 Seals for the refrigerant circuit......................................................................................................................................................................................................................................................................................................................................................................................................................... 6171
3.3 Refrigerant and refrigerant oil........................................................................................................................................................................................................................................................................................................................................................................................................................... 6173
3.3.1 Important repair instructions for refrigerant and refrigerant oil................................................................................................................................................................................................................................................................................................................................................................................... 6173
3.3.2 Refrigerant oil..................................................................................................................................................................................................................................................................................................................................................................................................................................... 6173
3.4 Handling pressure vessels................................................................................................................................................................................................................................................................................................................................................................................................................................. 6175
3.5 Handling refrigerant...................................................................................................................................................................................................................................................................................................................................................................................................................................... 6176
4 Identification.................................................................................................................................................................................................................................................................................................................................................................................................................................................. 6178
4.1 Label for refrigerant circuit............................................................................................................................................................................................................................................................................................................................................................................................................................. 6178
5 Technical data.................................................................................................................................................................................................................................................................................................................................................................................................................................................. 6179
5.1 Refrigerant capacities.................................................................................................................................................................................................................................................................................................................................................................................................................................... 6179
5.2 Refrigerant oil capacities................................................................................................................................................................................................................................................................................................................................................................................................................................ 6179
5.2.1 Approved refrigerant oils........................................................................................................................................................................................................................................................................................................................................................................................................................... 6179
5.2.2 Refrigerant oil capacities.......................................................................................................................................................................................................................................................................................................................................................................................................................... 6180
5.3 Safety data sheets........................................................................................................................................................................................................................................................................................................................................................................................................................................ 6180
6 Basic technical and physical principles......................................................................................................................................................................................................................................................................................................................................................................................................................... 6181
6.1 Basics of air conditioning technology..................................................................................................................................................................................................................................................................................................................................................................................................................... 6181
6.1.1 Basic physical principles of the air conditioner.................................................................................................................................................................................................................................................................................................................................................................................................... 6181
6.1.2 Refrigerant pressure and boiling point.............................................................................................................................................................................................................................................................................................................................................................................................................. 6182
6.1.3 Vapour pressure table for refrigerant............................................................................................................................................................................................................................................................................................................................................................................................................... 6182
6.2 Physical properties....................................................................................................................................................................................................................................................................................................................................................................................................................................... 6184
6.2.1 Refrigerant R1234yf................................................................................................................................................................................................................................................................................................................................................................................................................................. 6184
6.2.2 Possible dangers of refrigerant R1234yf............................................................................................................................................................................................................................................................................................................................................................................................................. 6185
6.2.3 Physical and chemical properties of refrigerant R1234yf............................................................................................................................................................................................................................................................................................................................................................................................. 6185
6.2.4 Critical point...................................................................................................................................................................................................................................................................................................................................................................................................................................... 6185
6.2.5 Environmental aspects of refrigerant R1234yf........................................................................................................................................................................................................................................................................................................................................................................................................ 6186
6.2.6 Trade names and designations of refrigerant R1234yf................................................................................................................................................................................................................................................................................................................................................................................................. 6186
6.2.7 Colour and odour of refrigerant R1234yf............................................................................................................................................................................................................................................................................................................................................................................................................. 6187
6.2.8 Vapour pressure of refrigerant R1234yf.............................................................................................................................................................................................................................................................................................................................................................................................................. 6187
6.2.9 Physical properties of refrigerant R1234yf.......................................................................................................................................................................................................................................................................................................................................................................................................... 6187
6.2.10 Behaviour of refrigerant R1234yf with metal and plastic............................................................................................................................................................................................................................................................................................................................................................................................ 6187
6.2.11 Critical temperature/critical pressure of refrigerant R1234yf...................................................................................................................................................................................................................................................................................................................................................................................... 6188
6.2.12 Water content of refrigerant R1234yf............................................................................................................................................................................................................................................................................................................................................................................................................... 6188
6.2.13 Flammability/decomposition of refrigerant R1234yf.................................................................................................................................................................................................................................................................................................................................................................................................. 6188
6.2.14 Filling factor of refrigerant R1234yf.............................................................................................................................................................................................................................................................................................................................................................................................................. 6188
6.2.15 Testing for leaks in a refrigerant circuit with refrigerant R1234yf................................................................................................................................................................................................................................................................................................................................................................................ 6189
6.2.16 Analysis of refrigerant R1234yf.................................................................................................................................................................................................................................................................................................................................................................................................................... 6189
6.2.17 Returning contaminated refrigerant R1234yf for analysis, treatment or disposal..................................................................................................................................................................................................................................................................................................................................................................... 6190
6.3 Product properties........................................................................................................................................................................................................................................................................................................................................................................................................................................ 6191
6.4 Function and task of the air conditioner.................................................................................................................................................................................................................................................................................................................................................................................................................. 6191
6.4.1 Method of operation................................................................................................................................................................................................................................................................................................................................................................................................................................. 6191
6.4.2 Comfort............................................................................................................................................................................................................................................................................................................................................................................................................................................. 6192
6.4.3 Environmental aspects............................................................................................................................................................................................................................................................................................................................................................................................................................... 6192
6.5 Further information resources............................................................................................................................................................................................................................................................................................................................................................................................................................. 6193
87 – Air conditioning system.......................................................................................................................................................................................................................................................................................................................................................................................................................................... 6194
1 Refrigerant circuit............................................................................................................................................................................................................................................................................................................................................................................................................................................. 6194
1.1 System overview - Refrigerant circuit..................................................................................................................................................................................................................................................................................................................................................................................................................... 6194
1.1.1 System overview - Refrigerant circuit with expansion valve and receiver............................................................................................................................................................................................................................................................................................................................................................................. 6194
1.1.2 System overview - Refrigerant circuit with restrictor and receiver.................................................................................................................................................................................................................................................................................................................................................................................. 6196
1.1.3 System overview - Refrigerant circuit with electrically driven air conditioner compressor (with and without battery cooling module)................................................................................................................................................................................................................................................................................................................. 6197
1.2 General description - Refrigerant circuit components...................................................................................................................................................................................................................................................................................................................................................................................................... 6200
1.2.1 Layout and function of the refrigerant circuit...................................................................................................................................................................................................................................................................................................................................................................................................... 6200
1.2.2 Mechanically driven air conditioner compressor...................................................................................................................................................................................................................................................................................................................................................................................................... 6202
1.2.3 Electrically driven air conditioner compressor...................................................................................................................................................................................................................................................................................................................................................................................................... 6204
1.2.4 Condenser........................................................................................................................................................................................................................................................................................................................................................................................................................................... 6207
1.2.5 Evaporator.......................................................................................................................................................................................................................................................................................................................................................................................................................................... 6207
1.2.6 Reservoir........................................................................................................................................................................................................................................................................................................................................................................................................................................... 6208
1.2.7 Heat exchanger for heat pump operation.............................................................................................................................................................................................................................................................................................................................................................................................................. 6209
1.2.8 Liquid collector.................................................................................................................................................................................................................................................................................................................................................................................................................................... 6209
1.2.9 Restrictor.......................................................................................................................................................................................................................................................................................................................................................................................................................................... 6210
1.2.10 Receiver........................................................................................................................................................................................................................................................................................................................................................................................................................................... 6211
1.2.11 Expansion valve (with and without shut-off valve).................................................................................................................................................................................................................................................................................................................................................................................................. 6212
1.2.12 Refrigerant shut-off valves........................................................................................................................................................................................................................................................................................................................................................................................................................ 6214
1.2.13 Refrigerant line with internal heat exchanger...................................................................................................................................................................................................................................................................................................................................................................................................... 6215
1.2.14 Refrigerant line quick-release coupling connections................................................................................................................................................................................................................................................................................................................................................................................................ 6216
1.2.15 Seals.............................................................................................................................................................................................................................................................................................................................................................................................................................................. 6217
1.2.16 Refrigerant circuit pipes and hoses................................................................................................................................................................................................................................................................................................................................................................................................................ 6217
1.2.17 Pressure relief valve.............................................................................................................................................................................................................................................................................................................................................................................................................................. 6217
1.2.18 Non-return valves.................................................................................................................................................................................................................................................................................................................................................................................................................................. 6218
1.2.19 Connections for quick-release couplings in the refrigerant circuit................................................................................................................................................................................................................................................................................................................................................................................. 6219
1.2.20 Connections with valve for switches in refrigerant circuit......................................................................................................................................................................................................................................................................................................................................................................................... 6223
1.2.21 Refrigerant circuit pressure senders and switches.................................................................................................................................................................................................................................................................................................................................................................................................. 6223
1.2.22 Refrigerant pressure and temperature senders....................................................................................................................................................................................................................................................................................................................................................................................................... 6224
1.2.23 Air conditioner compressor regulating valve -N280-................................................................................................................................................................................................................................................................................................................................................................................................. 6227
1.2.24 Refrigerant temperature sender..................................................................................................................................................................................................................................................................................................................................................................................................................... 6227
1.3 Possible problems......................................................................................................................................................................................................................................................................................................................................................................................................................................... 6228
1.3.1 Prerequisites for determining the cause of a problem................................................................................................................................................................................................................................................................................................................................................................................................ 6228
1.3.2 Possible problems................................................................................................................................................................................................................................................................................................................................................................................................................................... 6228
1.3.3 Smells from the heater and air conditioning unit.................................................................................................................................................................................................................................................................................................................................................................................................... 6230
1.4 Locating leaks............................................................................................................................................................................................................................................................................................................................................................................................................................................ 6232
1.4.1 General information on locating leaks in the refrigerant circuit.................................................................................................................................................................................................................................................................................................................................................................................... 6232
1.4.2 Finding leaks in the refrigerant circuit using an electronic leak detector.......................................................................................................................................................................................................................................................................................................................................................................... 6233
1.4.3 Finding leaks with the UV leak detector system...................................................................................................................................................................................................................................................................................................................................................................................................... 6235
1.4.4 Locating leaks via the vacuum test with the air conditioner service station or via the pressure test................................................................................................................................................................................................................................................................................................................................................ 6240
1.5 Replacing components...................................................................................................................................................................................................................................................................................................................................................................................................................................... 6241
1.5.1 General information on replacing components......................................................................................................................................................................................................................................................................................................................................................................................................... 6241
1.5.2 Replacing leaky or damaged components, empty refrigerant circuit (except for air conditioner compressor and receiver)............................................................................................................................................................................................................................................................................................................................... 6244
1.5.3 Replacing leaky or damaged components, charged refrigerant circuit (except for air conditioner compressor and receiver)............................................................................................................................................................................................................................................................................................................................. 6246
1.5.4 Replacing the air conditioner compressor without the necessity of cleaning the refrigerant circuit.................................................................................................................................................................................................................................................................................................................................................. 6247
1.5.5 Replacing the air conditioner compressor due to leaks or internal damage............................................................................................................................................................................................................................................................................................................................................................................ 6249
1.5.6 Replacing the desiccant cartridge/receiver after cleaning the refrigerant circuit................................................................................................................................................................................................................................................................................................................................................................... 6250
1.5.7 Replacing the receiver without the necessity of cleaning the refrigerant circuit.................................................................................................................................................................................................................................................................................................................................................................... 6252
1.5.8 Replacing the desiccant cartridge/desiccant bag without the necessity of cleaning the refrigerant circuit........................................................................................................................................................................................................................................................................................................................................... 6253
1.5.9 Removing and installing, replacing the air conditioner compressor regulating valve -N280-........................................................................................................................................................................................................................................................................................................................................................... 6254
1.6 Cleaning the refrigerant circuit.......................................................................................................................................................................................................................................................................................................................................................................................................................... 6258
1.6.1 General information on cleaning the refrigerant circuit............................................................................................................................................................................................................................................................................................................................................................................................. 6258
1.6.2 Preparatory work for cleaning the refrigerant circuit (flushing with refrigerant R1234yf)........................................................................................................................................................................................................................................................................................................................................................... 6260
1.6.3 Procedure for cleaning the refrigerant circuit...................................................................................................................................................................................................................................................................................................................................................................................................... 6262
1.6.4 Block diagrams for cleaning (flushing circuits) - Refrigerant circuit with expansion valve and receiver............................................................................................................................................................................................................................................................................................................................................. 6263
1.6.5 Block diagrams for cleaning (flushing circuits) - Refrigerant circuit with restrictor and reservoir (without high-voltage system)................................................................................................................................................................................................................................................................................................................... 6268
1.6.6 Block diagrams for cleaning (flushing circuits) - Vehicles with high-voltage system (without air conditioner auxiliary functions)................................................................................................................................................................................................................................................................................................................... 6271
1.6.7 Block diagrams for cleaning (flushing circuits) - Vehicles with high-voltage system (with air conditioner auxiliary functions, e.g. heat pump mode)................................................................................................................................................................................................................................................................................................. 6271
1.6.8 Adapters for connecting up flushing circuits........................................................................................................................................................................................................................................................................................................................................................................................................ 6272
1.6.9 General information on blowing out with compressed air or nitrogen.................................................................................................................................................................................................................................................................................................................................................................................. 6292
1.6.10 Blow out refrigerant circuit with compressed air or nitrogen....................................................................................................................................................................................................................................................................................................................................................................................... 6296
1.7 Check pressure values with a pressure gauge............................................................................................................................................................................................................................................................................................................................................................................................................... 6298
1.7.2 Pressure gauges permit the following test and measurement operations................................................................................................................................................................................................................................................................................................................................................................................ 6298
2 Working with the air conditioner service station................................................................................................................................................................................................................................................................................................................................................................................................................ 6301
2.1 Working with the air conditioner service station.......................................................................................................................................................................................................................................................................................................................................................................................................... 6301
2.2 Connecting the air conditioner service station to the refrigerant circuit................................................................................................................................................................................................................................................................................................................................................................................. 6303
2.3 Performing a gas analysis on the refrigerant.............................................................................................................................................................................................................................................................................................................................................................................................................. 6306
2.4 Draining the refrigerant circuit.......................................................................................................................................................................................................................................................................................................................................................................................................................... 6309
2.5 Evacuating the refrigerant circuit........................................................................................................................................................................................................................................................................................................................................................................................................................ 6311
2.6 Charging the refrigerant circuit.......................................................................................................................................................................................................................................................................................................................................................................................................................... 6318
2.7 Starting up air conditioner after charging................................................................................................................................................................................................................................................................................................................................................................................................................ 6321
2.8 Switching off the air conditioner service station and disconnecting from the refrigerant circuit.......................................................................................................................................................................................................................................................................................................................................................... 6323
2.9 Charging the reservoirs with refrigerant.................................................................................................................................................................................................................................................................................................................................................................................................................. 6325
2.10 Draining the air conditioner service station............................................................................................................................................................................................................................................................................................................................................................................................................. 6326
2.11 Cleaning the electrically driven air conditioner compressor.............................................................................................................................................................................................................................................................................................................................................................................................. 6326
2.12 Cleaning the refrigerant circuit......................................................................................................................................................................................................................................................................................................................................................................................................................... 6329
2.13 Filling contaminated refrigerant into a recycling cylinder for analysis, treatment or disposal........................................................................................................................................................................................................................................................................................................................................................... 6333
2.14 Checking pressure values................................................................................................................................................................................................................................................................................................................................................................................................................................. 6340
2.14.1 General information for checking pressure values in the refrigerant circuit........................................................................................................................................................................................................................................................................................................................................................................ 6340
2.14.2 Pressures and temperatures in refrigerant circuit.................................................................................................................................................................................................................................................................................................................................................................................................. 6342
2.14.3 Checking pressures in the refrigerant circuit with the ignition switched off....................................................................................................................................................................................................................................................................................................................................................................... 6346
2.14.4 Checking pressures with the air conditioner switched on in vehicles with mechanically driven air conditioner compressor............................................................................................................................................................................................................................................................................................................................ 6353
2.14.5 Checking pressures with the air conditioner switched on in vehicles with an electrically driven air conditioner compressor......................................................................................................................................................................................................................................................................................................................... 6375
3 Test equipment and tools........................................................................................................................................................................................................................................................................................................................................................................................................................................ 6427
3.1 Tools and materials that can be purchased from the sales centre or importer............................................................................................................................................................................................................................................................................................................................................................................... 6427
3.2 Tools and materials that are available from specialist retailers.......................................................................................................................................................................................................................................................................................................................................................................................... 6428
3.3 Tools that you can produce yourself....................................................................................................................................................................................................................................................................................................................................................................................................................... 6428
Automatic_gearbox_0B6__four-wheel_drive................................................................................................................................................................................................................................................................................................................................................................................................................................... 6429
00 – Technical data................................................................................................................................................................................................................................................................................................................................................................................................................................................... 6433
1 Identification.................................................................................................................................................................................................................................................................................................................................................................................................................................................. 6433
1.1 Gearbox identification.................................................................................................................................................................................................................................................................................................................................................................................................................................... 6433
2 Safety precautions.............................................................................................................................................................................................................................................................................................................................................................................................................................................. 6434
2.1 Safety precautions when working on vehicle................................................................................................................................................................................................................................................................................................................................................................................................................ 6434
2.2 Safety precautions when using testers and measuring instruments during a road test........................................................................................................................................................................................................................................................................................................................................................................ 6435
2.3 Notes on tow-starting and towing.......................................................................................................................................................................................................................................................................................................................................................................................................................... 6435
3 Repair instructions............................................................................................................................................................................................................................................................................................................................................................................................................................................. 6436
3.1 Rules for cleanliness..................................................................................................................................................................................................................................................................................................................................................................................................................................... 6436
3.2 General notes............................................................................................................................................................................................................................................................................................................................................................................................................................................. 6436
3.3 General repair instructions............................................................................................................................................................................................................................................................................................................................................................................................................................... 6437
3.4 Contact corrosion......................................................................................................................................................................................................................................................................................................................................................................................................................................... 6439
4 Technical data.................................................................................................................................................................................................................................................................................................................................................................................................................................................. 6440
4.1 Allocation of gearbox to engine........................................................................................................................................................................................................................................................................................................................................................................................................................... 6440
4.2 Capacities................................................................................................................................................................................................................................................................................................................................................................................................................................................ 6442
5 Transmission layout............................................................................................................................................................................................................................................................................................................................................................................................................................................. 6443
5.1 Transmission layout - four-wheel drive.................................................................................................................................................................................................................................................................................................................................................................................................................... 6443
32 – Torque converter................................................................................................................................................................................................................................................................................................................................................................................................................................................. 6444
1 Torque converter................................................................................................................................................................................................................................................................................................................................................................................................................................................ 6444
1.1 Exploded view - torque converter.......................................................................................................................................................................................................................................................................................................................................................................................................................... 6444
1.2 Identification of torque converter........................................................................................................................................................................................................................................................................................................................................................................................................................ 6445
1.3 Removing and installing torque converter.................................................................................................................................................................................................................................................................................................................................................................................................................. 6445
1.4 Draining torque converter................................................................................................................................................................................................................................................................................................................................................................................................................................. 6447
1.5 Checking torque converter................................................................................................................................................................................................................................................................................................................................................................................................................................. 6447
1.6 Removing and installing oil seal for torque converter..................................................................................................................................................................................................................................................................................................................................................................................................... 6447
37 – Controls, housing................................................................................................................................................................................................................................................................................................................................................................................................................................................ 6449
1 Selector mechanism.............................................................................................................................................................................................................................................................................................................................................................................................................................................. 6449
1.1 Exploded view - selector mechanism........................................................................................................................................................................................................................................................................................................................................................................................................................ 6449
1.2 Exploded view - selector lever handle..................................................................................................................................................................................................................................................................................................................................................................................................................... 6451
1.3 Exploded view - selector lever cable...................................................................................................................................................................................................................................................................................................................................................................................................................... 6452
1.4 Checking selector mechanism............................................................................................................................................................................................................................................................................................................................................................................................................................... 6452
1.5 Manual release from position P............................................................................................................................................................................................................................................................................................................................................................................................................................ 6454
1.6 Removing and installing selector mechanism................................................................................................................................................................................................................................................................................................................................................................................................................ 6455
1.7 Dismantling and assembling selector mechanism............................................................................................................................................................................................................................................................................................................................................................................................................. 6459
1.7.1 Removing and installing selector lever lock solenoid -N110-......................................................................................................................................................................................................................................................................................................................................................................................... 6459
1.7.2 Removing and installing selector lever sensors control unit -J587- and tiptronic switch -F189-...................................................................................................................................................................................................................................................................................................................................................... 6461
1.8 Removing and installing selector lever handle............................................................................................................................................................................................................................................................................................................................................................................................................. 6462
1.9 Detaching selector lever boot from selector lever handle.................................................................................................................................................................................................................................................................................................................................................................................................. 6465
1.10 Removing and installing selector lever position display -Y26-............................................................................................................................................................................................................................................................................................................................................................................................ 6466
1.11 Removing and installing selector lever cable............................................................................................................................................................................................................................................................................................................................................................................................................. 6466
1.12 Checking and adjusting selector lever cable.............................................................................................................................................................................................................................................................................................................................................................................................................. 6471
1.13 Adjusting selector lever cable to basic setting.......................................................................................................................................................................................................................................................................................................................................................................................................... 6472
1.14 Renewing selector shaft oil seal......................................................................................................................................................................................................................................................................................................................................................................................................................... 6476
2 Removing and installing gearbox................................................................................................................................................................................................................................................................................................................................................................................................................................. 6479
2.1 Removing gearbox.......................................................................................................................................................................................................................................................................................................................................................................................................................................... 6479
2.1.1 Removing gearbox, vehicles with 2.0 ltr. TFSI engine................................................................................................................................................................................................................................................................................................................................................................................................ 6479
2.1.2 Removing gearbox, vehicles with 3.2 ltr. FSI engine................................................................................................................................................................................................................................................................................................................................................................................................. 6489
2.1.3 Removing gearbox, vehicles with 4.2 ltr. FSI engine................................................................................................................................................................................................................................................................................................................................................................................................. 6499
2.1.4 Removing gearbox, vehicles with 3.0 ltr. TDI engine................................................................................................................................................................................................................................................................................................................................................................................................. 6508
2.2 Installing gearbox........................................................................................................................................................................................................................................................................................................................................................................................................................................ 6518
2.2.1 Installing gearbox, vehicles with 2.0 ltr. TFSI engine.............................................................................................................................................................................................................................................................................................................................................................................................. 6518
2.2.2 Installing gearbox, vehicles with 3.2 ltr. FSI engine............................................................................................................................................................................................................................................................................................................................................................................................... 6524
2.2.3 Installing gearbox, vehicles with 4.2 ltr. FSI engine............................................................................................................................................................................................................................................................................................................................................................................................... 6530
2.2.4 Installing gearbox, vehicles with 3.0 ltr. TDI engine............................................................................................................................................................................................................................................................................................................................................................................................... 6536
2.3 Tightening torques for gearbox............................................................................................................................................................................................................................................................................................................................................................................................................................ 6542
3 Assembly mountings.............................................................................................................................................................................................................................................................................................................................................................................................................................................. 6547
3.1 Exploded view - assembly mountings........................................................................................................................................................................................................................................................................................................................................................................................................................ 6547
3.2 Removing and installing tunnel cross member............................................................................................................................................................................................................................................................................................................................................................................................................... 6547
3.3 Removing and installing gearbox support with gearbox mounting............................................................................................................................................................................................................................................................................................................................................................................................. 6549
3.4 Removing and installing gearbox mounting.................................................................................................................................................................................................................................................................................................................................................................................................................. 6550
4 Transporting gearbox............................................................................................................................................................................................................................................................................................................................................................................................................................................ 6551
5 Securing to engine and gearbox support.......................................................................................................................................................................................................................................................................................................................................................................................................................... 6553
6 ATF............................................................................................................................................................................................................................................................................................................................................................................................................................................................. 6554
6.1 Checking ATF level........................................................................................................................................................................................................................................................................................................................................................................................................................................ 6554
6.2 Draining and filling ATF.................................................................................................................................................................................................................................................................................................................................................................................................................................. 6558
7 ATF circuit..................................................................................................................................................................................................................................................................................................................................................................................................................................................... 6563
7.1 Exploded view - ATF circuit............................................................................................................................................................................................................................................................................................................................................................................................................................... 6563
7.1.1 Exploded view - ATF circuit, 4-cyl. and 6-cyl. engines.............................................................................................................................................................................................................................................................................................................................................................................................. 6563
7.1.2 Exploded view - ATF circuit, 8-cyl. engines......................................................................................................................................................................................................................................................................................................................................................................................................... 6565
7.2 Cleaning ATF lines........................................................................................................................................................................................................................................................................................................................................................................................................................................ 6566
38 – Gears, control................................................................................................................................................................................................................................................................................................................................................................................................................................................... 6568
1 ATF system...................................................................................................................................................................................................................................................................................................................................................................................................................................................... 6568
1.1 Exploded view - ATF system................................................................................................................................................................................................................................................................................................................................................................................................................................ 6568
1.2 Removing and installing oil pan........................................................................................................................................................................................................................................................................................................................................................................................................................... 6570
1.3 Removing and installing ATF strainer...................................................................................................................................................................................................................................................................................................................................................................................................................... 6572
2 Mechatronic unit................................................................................................................................................................................................................................................................................................................................................................................................................................................ 6574
2.1 Removing and installing mechatronic unit.................................................................................................................................................................................................................................................................................................................................................................................................................. 6574
2.2 Removing and installing wiring harness in gearbox......................................................................................................................................................................................................................................................................................................................................................................................................... 6578
39 – Final drive - front differential................................................................................................................................................................................................................................................................................................................................................................................................................................. 6580
1 Final drive..................................................................................................................................................................................................................................................................................................................................................................................................................................................... 6580
1.1 Exploded view - final drive............................................................................................................................................................................................................................................................................................................................................................................................................................... 6580
1.2 Renewing O-ring on cover for front final drive............................................................................................................................................................................................................................................................................................................................................................................................................ 6581
2 Gear oil........................................................................................................................................................................................................................................................................................................................................................................................................................................................ 6583
2.1 Checking gear oil level................................................................................................................................................................................................................................................................................................................................................................................................................................... 6583
2.1.1 Checking gear oil level, front final drive.......................................................................................................................................................................................................................................................................................................................................................................................................... 6583
2.1.2 Checking gear oil level, transfer box............................................................................................................................................................................................................................................................................................................................................................................................................... 6584
2.2 Draining and filling gear oil............................................................................................................................................................................................................................................................................................................................................................................................................................. 6585
2.2.1 Draining and filling gear oil, front final drive.................................................................................................................................................................................................................................................................................................................................................................................................... 6585
2.2.2 Draining and filling gear oil, transfer box......................................................................................................................................................................................................................................................................................................................................................................................................... 6586
3 Oil seals....................................................................................................................................................................................................................................................................................................................................................................................................................................................... 6589
3.1 Renewing oil seal (left-side)............................................................................................................................................................................................................................................................................................................................................................................................................................. 6589
3.2 Renewing oil seal (right-side)............................................................................................................................................................................................................................................................................................................................................................................................................................ 6592
4 Differential.................................................................................................................................................................................................................................................................................................................................................................................................................................................... 6594
4.1 Removing and installing flange shaft (left-side).......................................................................................................................................................................................................................................................................................................................................................................................................... 6594
4.2 Removing and installing flange shaft (right-side)......................................................................................................................................................................................................................................................................................................................................................................................................... 6595
5 Centre differential............................................................................................................................................................................................................................................................................................................................................................................................................................................. 6598
5.1 Exploded view - centre differential....................................................................................................................................................................................................................................................................................................................................................................................................................... 6598
5.2 Removing and installing centre differential............................................................................................................................................................................................................................................................................................................................................................................................................... 6600
5.3 Renewing oil seal for flange shaft (rear)................................................................................................................................................................................................................................................................................................................................................................................................................. 6604
5.4 Renewing ball bearing for flange shaft (rear)............................................................................................................................................................................................................................................................................................................................................................................................................. 6606
5.5 Renewing ball bearing for centre differential............................................................................................................................................................................................................................................................................................................................................................................................................. 6608
6 Gearbox control system.......................................................................................................................................................................................................................................................................................................................................................................................................................................... 6611
6.1 Overview of fitting locations - gearbox control system.................................................................................................................................................................................................................................................................................................................................................................................................... 6611
Auxiliary_heater__supplementary_heater.................................................................................................................................................................................................................................................................................................................................................................................................................................... 6614
00 – Technical data................................................................................................................................................................................................................................................................................................................................................................................................................................................... 6618
1 General notes................................................................................................................................................................................................................................................................................................................................................................................................................................................... 6618
1.1 Type plates............................................................................................................................................................................................................................................................................................................................................................................................................................................... 6618
1.2 Notes on operation of auxiliary/supplementary heater on vehicles with diesel engine....................................................................................................................................................................................................................................................................................................................................................................... 6619
1.3 Starting conditions for auxiliary/supplementary heater.................................................................................................................................................................................................................................................................................................................................................................................................... 6619
1.4 Notes on auxiliary heater................................................................................................................................................................................................................................................................................................................................................................................................................................. 6620
1.4.1 Notes on auxiliary heater........................................................................................................................................................................................................................................................................................................................................................................................................................... 6620
1.4.2 Switching on auxiliary heater....................................................................................................................................................................................................................................................................................................................................................................................................................... 6621
1.4.3 Auxiliary heater heating mode....................................................................................................................................................................................................................................................................................................................................................................................................................... 6625
1.5 Operating sequence for auxiliary heater................................................................................................................................................................................................................................................................................................................................................................................................................... 6628
1.5.1 Switching off auxiliary heater...................................................................................................................................................................................................................................................................................................................................................................................................................... 6628
1.5.2 Auxiliary ventilation............................................................................................................................................................................................................................................................................................................................................................................................................................... 6629
1.5.3 Measured values and components monitored during operating sequence.................................................................................................................................................................................................................................................................................................................................................................................. 6630
1.5.4 Sequence with required heat output between 50 and 100 %............................................................................................................................................................................................................................................................................................................................................................................................. 6632
1.5.5 Sequence with required heat output less than 50 %................................................................................................................................................................................................................................................................................................................................................................................................... 6632
1.6 Activation of heater coolant shut-off valve............................................................................................................................................................................................................................................................................................................................................................................................................... 6633
1.7 Rules for cleanliness when working on the auxiliary/supplementary heater and fuel system.................................................................................................................................................................................................................................................................................................................................................................. 6634
1.8 Overview of components for auxiliary heater in vehicle.................................................................................................................................................................................................................................................................................................................................................................................................... 6636
2 Safety precautions.............................................................................................................................................................................................................................................................................................................................................................................................................................................. 6638
2.1 Safety precautions when working on vehicles with start/stop system........................................................................................................................................................................................................................................................................................................................................................................................ 6638
2.2 Safety precautions when working on vehicles with auxiliary/supplementary heater........................................................................................................................................................................................................................................................................................................................................................................... 6638
3 Repair instructions............................................................................................................................................................................................................................................................................................................................................................................................................................................. 6640
3.1 General repair instructions............................................................................................................................................................................................................................................................................................................................................................................................................................... 6640
3.2 Contact corrosion......................................................................................................................................................................................................................................................................................................................................................................................................................................... 6640
82 – Auxiliary heating................................................................................................................................................................................................................................................................................................................................................................................................................................................ 6642
1 Overview of fitting locations - auxiliary/supplementary heater.................................................................................................................................................................................................................................................................................................................................................................................................. 6642
1.1 Overview of fitting locations - components not located in passenger compartment........................................................................................................................................................................................................................................................................................................................................................................... 6642
1.2 Overview of fitting locations - components in passenger compartment (front)............................................................................................................................................................................................................................................................................................................................................................................... 6648
1.3 Overview of fitting locations - components in passenger compartment (rear)................................................................................................................................................................................................................................................................................................................................................................................ 6654
2 Auxiliary/supplementary heater.................................................................................................................................................................................................................................................................................................................................................................................................................................. 6657
2.1 General notes............................................................................................................................................................................................................................................................................................................................................................................................................................................. 6657
2.2 Overview of fitting locations - auxiliary/supplementary heater............................................................................................................................................................................................................................................................................................................................................................................................ 6658
2.2.1 Overview of fitting locations - auxiliary/supplementary heater, Audi A4, Audi A5.................................................................................................................................................................................................................................................................................................................................................................... 6658
2.2.2 Overview of fitting locations - auxiliary/supplementary heater, Audi Q5............................................................................................................................................................................................................................................................................................................................................................................. 6662
2.3 Exploded view - components inside auxiliary/supplementary heater.......................................................................................................................................................................................................................................................................................................................................................................................... 6668
2.4 Removing and installing auxiliary/supplementary heater.................................................................................................................................................................................................................................................................................................................................................................................................... 6675
2.5 Dismantling and assembling auxiliary/supplementary heater................................................................................................................................................................................................................................................................................................................................................................................................. 6684
2.6 Removing and installing air intake silencer............................................................................................................................................................................................................................................................................................................................................................................................................... 6687
2.7 Removing and installing circulation pump -V55-............................................................................................................................................................................................................................................................................................................................................................................................................ 6688
2.8 Removing and installing exhaust system.................................................................................................................................................................................................................................................................................................................................................................................................................... 6691
2.9 Removing and installing bracket for auxiliary/supplementary heater........................................................................................................................................................................................................................................................................................................................................................................................ 6693
2.10 Removing and installing auxiliary heater control unit -J364-............................................................................................................................................................................................................................................................................................................................................................................................. 6695
2.11 Removing and installing temperature sensor -G18-......................................................................................................................................................................................................................................................................................................................................................................................................... 6697
2.12 Removing and installing temperature sensor 2 for supplementary and auxiliary heating -G587-.............................................................................................................................................................................................................................................................................................................................................................. 6698
2.13 Removing and installing flame monitor -G64-.............................................................................................................................................................................................................................................................................................................................................................................................................. 6699
2.14 Removing and installing glow plug for heater -Q9-........................................................................................................................................................................................................................................................................................................................................................................................................ 6700
2.15 Removing and installing fuel pre-heating heater element -Z66-............................................................................................................................................................................................................................................................................................................................................................................................ 6701
2.16 Removing and installing combustion air blower -V6-....................................................................................................................................................................................................................................................................................................................................................................................................... 6703
2.17 Removing and installing burner element................................................................................................................................................................................................................................................................................................................................................................................................................... 6703
2.18 Removing and installing heat exchanger................................................................................................................................................................................................................................................................................................................................................................................................................... 6705
2.19 Pin assignment for auxiliary/supplementary heater........................................................................................................................................................................................................................................................................................................................................................................................................ 6705
2.20 Checking electrical components of auxiliary heater....................................................................................................................................................................................................................................................................................................................................................................................................... 6707
2.20.1 Checking activation and electrical connections of auxiliary heater................................................................................................................................................................................................................................................................................................................................................................................. 6707
2.20.2 Preparation for checking auxiliary heater components............................................................................................................................................................................................................................................................................................................................................................................................... 6708
2.20.3 Checking glow plug for heater -Q9-................................................................................................................................................................................................................................................................................................................................................................................................................. 6709
2.20.4 Checking combustion air blower -V6-................................................................................................................................................................................................................................................................................................................................................................................................................ 6710
2.20.5 Checking flame monitor -G64-....................................................................................................................................................................................................................................................................................................................................................................................................................... 6710
2.20.6 Checking temperature sensor -G18-.................................................................................................................................................................................................................................................................................................................................................................................................................. 6711
2.20.7 Checking temperature sensor 2 for supplementary and auxiliary heating -G587-....................................................................................................................................................................................................................................................................................................................................................................... 6712
2.20.8 Checking fuel pre-heating heater element -Z66-..................................................................................................................................................................................................................................................................................................................................................................................................... 6713
3 Coolant circuit with auxiliary/supplementary heater............................................................................................................................................................................................................................................................................................................................................................................................................. 6714
3.1 General notes............................................................................................................................................................................................................................................................................................................................................................................................................................................. 6714
3.2 Connection diagram - coolant hoses........................................................................................................................................................................................................................................................................................................................................................................................................................ 6715
3.2.1 Connection diagram - coolant hoses, vehicles without non-return valve............................................................................................................................................................................................................................................................................................................................................................................... 6715
3.2.2 Connection diagram - coolant hoses, vehicles with non-return valve.................................................................................................................................................................................................................................................................................................................................................................................. 6718
3.3 Operation of heater coolant shut-off valve................................................................................................................................................................................................................................................................................................................................................................................................................ 6722
3.4 Removing and installing heater coolant shut-off valve..................................................................................................................................................................................................................................................................................................................................................................................................... 6723
3.5 Bleeding coolant circuit.................................................................................................................................................................................................................................................................................................................................................................................................................................. 6725
4 Fuel supply system.............................................................................................................................................................................................................................................................................................................................................................................................................................................. 6728
4.1 Overview of fitting locations - fuel supply system........................................................................................................................................................................................................................................................................................................................................................................................................ 6728
4.2 Overview - metering pump -V54-............................................................................................................................................................................................................................................................................................................................................................................................................................ 6731
4.3 Fuel take-off from fuel tank.............................................................................................................................................................................................................................................................................................................................................................................................................................. 6731
4.4 Fuel delivery unit in fuel tank........................................................................................................................................................................................................................................................................................................................................................................................................................... 6733
4.5 Filling fuel line to metering pump -V54- with fuel, bleeding.............................................................................................................................................................................................................................................................................................................................................................................................. 6735
4.6 Releasing quick-release coupling at fuel line for auxiliary heater........................................................................................................................................................................................................................................................................................................................................................................................ 6735
4.7 Routing of fuel pipe to auxiliary heater.................................................................................................................................................................................................................................................................................................................................................................................................................. 6736
4.8 Checking CO2 content in auxiliary heater exhaust gas...................................................................................................................................................................................................................................................................................................................................................................................................... 6737
4.9 Checking fuel delivery rate............................................................................................................................................................................................................................................................................................................................................................................................................................... 6741
4.10 Removing and installing metering pump -V54-.............................................................................................................................................................................................................................................................................................................................................................................................................. 6747
5 Auxiliary/supplementary heater control.......................................................................................................................................................................................................................................................................................................................................................................................................................... 6752
5.1 Functional description.................................................................................................................................................................................................................................................................................................................................................................................................................................... 6752
5.2 Overview of activation of auxiliary heater with remote control............................................................................................................................................................................................................................................................................................................................................................................................ 6754
5.3 Activating and deactivating auxiliary heating/auxiliary ventilation via Multi Media Interface (MMI)....................................................................................................................................................................................................................................................................................................................................................... 6755
6 Further control components...................................................................................................................................................................................................................................................................................................................................................................................................................................... 6757
6.1 Removing and installing remote control receiver for auxiliary heater -R64-................................................................................................................................................................................................................................................................................................................................................................................ 6757
6.2 Auxiliary heater remote control buttons and indicator lamp................................................................................................................................................................................................................................................................................................................................................................................................ 6758
6.3 Renewing batteries of remote control for auxiliary heater................................................................................................................................................................................................................................................................................................................................................................................................. 6761
6.4 Adaption of remote control for auxiliary heater........................................................................................................................................................................................................................................................................................................................................................................................................... 6762
Body_Repairs.............................................................................................................................................................................................................................................................................................................................................................................................................................................................. 6764
00 – Technical data................................................................................................................................................................................................................................................................................................................................................................................................................................................... 6770
1 General notes................................................................................................................................................................................................................................................................................................................................................................................................................................................... 6770
2 Vehicle identification data..................................................................................................................................................................................................................................................................................................................................................................................................................................... 6771
2.1 Type plate and vehicle identification number.............................................................................................................................................................................................................................................................................................................................................................................................................. 6771
2.2 Vehicle data sticker...................................................................................................................................................................................................................................................................................................................................................................................................................................... 6771
3 Aluminium panels................................................................................................................................................................................................................................................................................................................................................................................................................................................ 6772
3.1 Wing panels............................................................................................................................................................................................................................................................................................................................................................................................................................................... 6772
4 Galvanised body panels, high-strength and ultra-high strength steel............................................................................................................................................................................................................................................................................................................................................................................................ 6773
5 Moulded foam inserts............................................................................................................................................................................................................................................................................................................................................................................................................................................ 6778
6 Repairing thread for seat belt anchorage........................................................................................................................................................................................................................................................................................................................................................................................................................ 6780
7 Body panel gaps/shut lines...................................................................................................................................................................................................................................................................................................................................................................................................................................... 6781
8 Laser welding................................................................................................................................................................................................................................................................................................................................................................................................................................................... 6785
9 Bonded joints................................................................................................................................................................................................................................................................................................................................................................................................................................................... 6786
9.1 Bonded joints............................................................................................................................................................................................................................................................................................................................................................................................................................................. 6786
9.2 Spot-welded/bonded joints................................................................................................................................................................................................................................................................................................................................................................................................................................. 6786
9.3 Inspecting and repairing bonded joints.................................................................................................................................................................................................................................................................................................................................................................................................................... 6786
9.4 Repair methods for replacing body parts................................................................................................................................................................................................................................................................................................................................................................................................................... 6786
10 Straightening jig.............................................................................................................................................................................................................................................................................................................................................................................................................................................. 6788
11 Body dimensions................................................................................................................................................................................................................................................................................................................................................................................................................................................ 6789
50 – Body - front..................................................................................................................................................................................................................................................................................................................................................................................................................................................... 6799
1 Intermediate piece - Renewal ................................................................................................................................................................................................................................................................................................................................................................................................................................... 6799
1.1 Tools..................................................................................................................................................................................................................................................................................................................................................................................................................................................... 6799
1.2 Procedure................................................................................................................................................................................................................................................................................................................................................................................................................................................. 6800
2 Upper longitudinal member for wheel housing - Renewal........................................................................................................................................................................................................................................................................................................................................................................................................... 6803
2.1 Tools..................................................................................................................................................................................................................................................................................................................................................................................................................................................... 6803
2.2 Procedure................................................................................................................................................................................................................................................................................................................................................................................................................................................. 6804
3 Suspension strut mounting - Renewal ............................................................................................................................................................................................................................................................................................................................................................................................................................ 6807
3.1 Tools..................................................................................................................................................................................................................................................................................................................................................................................................................................................... 6807
3.2 Procedure................................................................................................................................................................................................................................................................................................................................................................................................................................................. 6808
4 Front longitudinal member - Partial renewal..................................................................................................................................................................................................................................................................................................................................................................................................................... 6813
4.1 Tools..................................................................................................................................................................................................................................................................................................................................................................................................................................................... 6813
4.2 Procedure................................................................................................................................................................................................................................................................................................................................................................................................................................................. 6813
5 Front longitudinal member - Renewal............................................................................................................................................................................................................................................................................................................................................................................................................................. 6819
5.1 Tools..................................................................................................................................................................................................................................................................................................................................................................................................................................................... 6819
5.2 Procedure................................................................................................................................................................................................................................................................................................................................................................................................................................................. 6820
6 Longitudinal member reinforcement (front) - Renewal............................................................................................................................................................................................................................................................................................................................................................................................................. 6828
6.1 Tools..................................................................................................................................................................................................................................................................................................................................................................................................................................................... 6828
6.2 Procedure................................................................................................................................................................................................................................................................................................................................................................................................................................................. 6829
51 – Body - centre.................................................................................................................................................................................................................................................................................................................................................................................................................................................... 6832
1 Permitted separating cuts on complete side panel................................................................................................................................................................................................................................................................................................................................................................................................................ 6832
2 Roof - Renewal.................................................................................................................................................................................................................................................................................................................................................................................................................................................. 6834
2.1 Tools..................................................................................................................................................................................................................................................................................................................................................................................................................................................... 6834
2.2 Procedure................................................................................................................................................................................................................................................................................................................................................................................................................................................. 6835
3 Roof - Renewal (version with tilting sunroof).................................................................................................................................................................................................................................................................................................................................................................................................................. 6846
3.1 Tools..................................................................................................................................................................................................................................................................................................................................................................................................................................................... 6846
3.2 Procedure................................................................................................................................................................................................................................................................................................................................................................................................................................................. 6847
4 Roof - Renewal (Sportback)..................................................................................................................................................................................................................................................................................................................................................................................................................................... 6855
4.1 Tools..................................................................................................................................................................................................................................................................................................................................................................................................................................................... 6856
4.2 Procedure................................................................................................................................................................................................................................................................................................................................................................................................................................................. 6858
5 Roof side member - Renewal ..................................................................................................................................................................................................................................................................................................................................................................................................................................... 6874
5.1 Tools..................................................................................................................................................................................................................................................................................................................................................................................................................................................... 6874
5.2 Procedure................................................................................................................................................................................................................................................................................................................................................................................................................................................. 6875
6 Roof side member - foam-filling (Sportback)..................................................................................................................................................................................................................................................................................................................................................................................................................... 6879
6.1 Tools..................................................................................................................................................................................................................................................................................................................................................................................................................................................... 6879
6.2 Procedure................................................................................................................................................................................................................................................................................................................................................................................................................................................. 6880
7 Roof side member - foam-filling................................................................................................................................................................................................................................................................................................................................................................................................................................. 6886
8 Front roof cross member - Renewal............................................................................................................................................................................................................................................................................................................................................................................................................................... 6897
8.1 Tools..................................................................................................................................................................................................................................................................................................................................................................................................................................................... 6897
8.2 Procedure................................................................................................................................................................................................................................................................................................................................................................................................................................................. 6897
9 Rear roof frame - Renewal....................................................................................................................................................................................................................................................................................................................................................................................................................................... 6900
9.1 Tools..................................................................................................................................................................................................................................................................................................................................................................................................................................................... 6900
9.2 Procedure................................................................................................................................................................................................................................................................................................................................................................................................................................................. 6900
10 Rear roof cross member - Renewal (Sportback)................................................................................................................................................................................................................................................................................................................................................................................................................... 6903
10.1 Tools.................................................................................................................................................................................................................................................................................................................................................................................................................................................... 6904
10.2 Procedure................................................................................................................................................................................................................................................................................................................................................................................................................................................ 6905
11 A-pillar - Renewal (Coupé and Sportback identical)............................................................................................................................................................................................................................................................................................................................................................................................................. 6909
11.1 Tools.................................................................................................................................................................................................................................................................................................................................................................................................................................................... 6909
11.2 Procedure................................................................................................................................................................................................................................................................................................................................................................................................................................................ 6910
12 Inner A-pillar - Renewal (Coupé and Sportback identical)....................................................................................................................................................................................................................................................................................................................................................................................................... 6917
12.1 Tools.................................................................................................................................................................................................................................................................................................................................................................................................................................................... 6917
12.2 Procedure................................................................................................................................................................................................................................................................................................................................................................................................................................................ 6918
13 Outer B-pillar - Renewal (Sportback)........................................................................................................................................................................................................................................................................................................................................................................................................................... 6922
13.1 Tools.................................................................................................................................................................................................................................................................................................................................................................................................................................................... 6923
13.2 Procedure................................................................................................................................................................................................................................................................................................................................................................................................................................................ 6923
14 Inner B-pillar - Renewal (Coupé)............................................................................................................................................................................................................................................................................................................................................................................................................................... 6928
14.1 Tools.................................................................................................................................................................................................................................................................................................................................................................................................................................................... 6928
14.2 Procedure................................................................................................................................................................................................................................................................................................................................................................................................................................................ 6929
15 Inner B-pillar - Partial renewal (Coupé)....................................................................................................................................................................................................................................................................................................................................................................................................................... 6935
15.1 Tools.................................................................................................................................................................................................................................................................................................................................................................................................................................................... 6935
15.2 Procedure................................................................................................................................................................................................................................................................................................................................................................................................................................................ 6936
16 Inner B-pillar - Partial renewal (Sportback) .................................................................................................................................................................................................................................................................................................................................................................................................................. 6942
16.1 Tools.................................................................................................................................................................................................................................................................................................................................................................................................................................................... 6943
16.2 Procedure................................................................................................................................................................................................................................................................................................................................................................................................................................................ 6944
17 Outer side member - Renewal (Sportback)........................................................................................................................................................................................................................................................................................................................................................................................................................ 6956
17.1 Tools.................................................................................................................................................................................................................................................................................................................................................................................................................................................... 6957
17.2 Procedure................................................................................................................................................................................................................................................................................................................................................................................................................................................ 6957
18 Inner side member - Renewal (Coupé and Sportback identical).................................................................................................................................................................................................................................................................................................................................................................................................... 6962
18.1 Tools.................................................................................................................................................................................................................................................................................................................................................................................................................................................... 6962
18.2 Procedure................................................................................................................................................................................................................................................................................................................................................................................................................................................ 6962
19 Inner side member - Partial renewal (Coupé and Sportback identical)............................................................................................................................................................................................................................................................................................................................................................................................ 6970
19.1 Tools.................................................................................................................................................................................................................................................................................................................................................................................................................................................... 6970
19.2 Procedure................................................................................................................................................................................................................................................................................................................................................................................................................................................ 6970
20 Inner side member reinforcement - Renewal (Coupé and Sportback identical)...................................................................................................................................................................................................................................................................................................................................................................................... 6975
20.1 Tools.................................................................................................................................................................................................................................................................................................................................................................................................................................................... 6975
20.2 Procedure................................................................................................................................................................................................................................................................................................................................................................................................................................................ 6976
53 – Body - rear...................................................................................................................................................................................................................................................................................................................................................................................................................................................... 6981
1 Permitted separating cuts on complete side panel................................................................................................................................................................................................................................................................................................................................................................................................................ 6981
2 Upper cross panel - Renewal..................................................................................................................................................................................................................................................................................................................................................................................................................................... 6983
2.1 Tools..................................................................................................................................................................................................................................................................................................................................................................................................................................................... 6983
2.2 Procedure................................................................................................................................................................................................................................................................................................................................................................................................................................................. 6983
3 Upper cross panel - Renewal (Sportback) ........................................................................................................................................................................................................................................................................................................................................................................................................................ 6986
3.1 Tools..................................................................................................................................................................................................................................................................................................................................................................................................................................................... 6987
3.2 Procedure................................................................................................................................................................................................................................................................................................................................................................................................................................................. 6988
4 Rear cross panel - Renewal (Coupé).............................................................................................................................................................................................................................................................................................................................................................................................................................. 6993
4.1 Tools..................................................................................................................................................................................................................................................................................................................................................................................................................................................... 6993
4.2 Procedure................................................................................................................................................................................................................................................................................................................................................................................................................................................. 6993
5 Rear cross panel - Renewal (Sportback) ......................................................................................................................................................................................................................................................................................................................................................................................................................... 6996
5.1 Tools..................................................................................................................................................................................................................................................................................................................................................................................................................................................... 6997
5.2 Procedure................................................................................................................................................................................................................................................................................................................................................................................................................................................. 6998
6 Inner cross panel - Renewal (Coupé and Sportback identical)..................................................................................................................................................................................................................................................................................................................................................................................................... 7001
6.1 Tools..................................................................................................................................................................................................................................................................................................................................................................................................................................................... 7001
6.2 Procedure................................................................................................................................................................................................................................................................................................................................................................................................................................................. 7001
7 Tail light mounting - Renewal (Coupé and Sportback identical)................................................................................................................................................................................................................................................................................................................................................................................................... 7004
7.1 Tools..................................................................................................................................................................................................................................................................................................................................................................................................................................................... 7004
7.2 Procedure................................................................................................................................................................................................................................................................................................................................................................................................................................................. 7004
8 Rear longitudinal member - Partial renewal (Coupé and Sportback identical)...................................................................................................................................................................................................................................................................................................................................................................................... 7007
8.1 Tools..................................................................................................................................................................................................................................................................................................................................................................................................................................................... 7007
8.2 Procedure................................................................................................................................................................................................................................................................................................................................................................................................................................................. 7008
9 Rear longitudinal member - Renewal (Coupé and Sportback identical).............................................................................................................................................................................................................................................................................................................................................................................................. 7012
9.1 Tools..................................................................................................................................................................................................................................................................................................................................................................................................................................................... 7012
9.2 Procedure................................................................................................................................................................................................................................................................................................................................................................................................................................................. 7013
10 Side panel - Renewal (Coupé).................................................................................................................................................................................................................................................................................................................................................................................................................................. 7020
10.1 Tools.................................................................................................................................................................................................................................................................................................................................................................................................................................................... 7020
10.2 Procedure................................................................................................................................................................................................................................................................................................................................................................................................................................................ 7021
11 Side panel - Renewal (Sportback)............................................................................................................................................................................................................................................................................................................................................................................................................................... 7031
11.1 Tools.................................................................................................................................................................................................................................................................................................................................................................................................................................................... 7032
11.2 Procedure................................................................................................................................................................................................................................................................................................................................................................................................................................................ 7032
12 Rear wheel housing - Renewal (Coupé and Sportback identical)................................................................................................................................................................................................................................................................................................................................................................................................... 7041
12.1 Tools.................................................................................................................................................................................................................................................................................................................................................................................................................................................... 7041
12.2 Procedure................................................................................................................................................................................................................................................................................................................................................................................................................................................ 7042
13 Spare wheel well - Renewal (Coupé and Sportback identical).................................................................................................................................................................................................................................................................................................................................................................................................... 7046
13.1 Tools.................................................................................................................................................................................................................................................................................................................................................................................................................................................... 7046
13.2 Procedure................................................................................................................................................................................................................................................................................................................................................................................................................................................ 7046
Body_Repairs__General_Body_Repairs........................................................................................................................................................................................................................................................................................................................................................................................................................................ 7050
1 General notes....................................................................................................................................................................................................................................................................................................................................................................................................................................................... 7056
1.1 Diagnosis of accident vehicles................................................................................................................................................................................................................................................................................................................................................................................................................................ 7056
1.2 General notes on body repairs................................................................................................................................................................................................................................................................................................................................................................................................................................. 7056
1.3 Condition in which body and/or individual parts must be delivered to paintshop................................................................................................................................................................................................................................................................................................................................................................................ 7056
1.4 Straightening................................................................................................................................................................................................................................................................................................................................................................................................................................................. 7056
1.5 Separating cuts............................................................................................................................................................................................................................................................................................................................................................................................................................................... 7057
1.6 Body sub-parts and part sections.............................................................................................................................................................................................................................................................................................................................................................................................................................. 7057
1.7 Original joint................................................................................................................................................................................................................................................................................................................................................................................................................................................ 7057
1.8 Galvanised body parts......................................................................................................................................................................................................................................................................................................................................................................................................................................... 7057
1.9 Removing remaining material................................................................................................................................................................................................................................................................................................................................................................................................................................... 7057
1.10 New parts.................................................................................................................................................................................................................................................................................................................................................................................................................................................... 7057
1.11 Replacement parts............................................................................................................................................................................................................................................................................................................................................................................................................................................ 7058
2 Safety notes........................................................................................................................................................................................................................................................................................................................................................................................................................................................ 7059
2.1 Removing components........................................................................................................................................................................................................................................................................................................................................................................................................................................... 7059
2.2 Battery, welding operations................................................................................................................................................................................................................................................................................................................................................................................................................................... 7059
2.3 Electronic control units...................................................................................................................................................................................................................................................................................................................................................................................................................................... 7059
2.4 Procedure for electronic control units following accident repairs............................................................................................................................................................................................................................................................................................................................................................................................. 7059
2.5 Paintwork, glass, upholstery, trim panels..................................................................................................................................................................................................................................................................................................................................................................................................................... 7059
2.6 Fuel tank and fuel pipes...................................................................................................................................................................................................................................................................................................................................................................................................................................... 7059
2.7 Air conditioner............................................................................................................................................................................................................................................................................................................................................................................................................................................... 7060
2.8 Airbag system................................................................................................................................................................................................................................................................................................................................................................................................................................................. 7060
2.9 Checking seat belts........................................................................................................................................................................................................................................................................................................................................................................................................................................... 7061
2.10 Working on vehicles with belt tensioners..................................................................................................................................................................................................................................................................................................................................................................................................................... 7061
2.11 Cutting, straightening and/or dent removal work on vehicles with airbag...................................................................................................................................................................................................................................................................................................................................................................................... 7062
2.12 Removing seats with side airbag.............................................................................................................................................................................................................................................................................................................................................................................................................................. 7062
3 Anti-corrosion measures............................................................................................................................................................................................................................................................................................................................................................................................................................................. 7063
3.1 Anti-corrosion protection..................................................................................................................................................................................................................................................................................................................................................................................................................................... 7063
3.2 Long-term body protection..................................................................................................................................................................................................................................................................................................................................................................................................................................... 7063
3.3 Notes on warranty............................................................................................................................................................................................................................................................................................................................................................................................................................................. 7063
3.4 Electrolytic galvanisation.................................................................................................................................................................................................................................................................................................................................................................................................................................... 7063
3.5 Hot-dip galvanisation......................................................................................................................................................................................................................................................................................................................................................................................................................................... 7064
4 Notes on disposal................................................................................................................................................................................................................................................................................................................................................................................................................................................... 7065
4.1 Active environmental protection at the factory................................................................................................................................................................................................................................................................................................................................................................................................................ 7065
4.2 Recycling means:.............................................................................................................................................................................................................................................................................................................................................................................................................................................. 7065
4.3 The basic rules for environmental protection are:............................................................................................................................................................................................................................................................................................................................................................................................................. 7065
4.4 Recycling..................................................................................................................................................................................................................................................................................................................................................................................................................................................... 7065
4.5 Plastics...................................................................................................................................................................................................................................................................................................................................................................................................................................................... 7066
4.6 Disposal...................................................................................................................................................................................................................................................................................................................................................................................................................................................... 7067
4.7 Airbag........................................................................................................................................................................................................................................................................................................................................................................................................................................................ 7068
4.8 Protection against contact corrosion.......................................................................................................................................................................................................................................................................................................................................................................................................................... 7069
5 Expanded foam inserts............................................................................................................................................................................................................................................................................................................................................................................................................................................... 7070
6 Explanation of symbols.............................................................................................................................................................................................................................................................................................................................................................................................................................................. 7071
6.1 Symbols for welding operations................................................................................................................................................................................................................................................................................................................................................................................................................................ 7071
6.2 Symbols for work procedures................................................................................................................................................................................................................................................................................................................................................................................................................................... 7071
6.3 Cavity sealing................................................................................................................................................................................................................................................................................................................................................................................................................................................ 7072
7 Body - Bonded joints................................................................................................................................................................................................................................................................................................................................................................................................................................................ 7073
8 Sheet steel repairs................................................................................................................................................................................................................................................................................................................................................................................................................................................. 7076
8.1 Extra-high-strength body panels............................................................................................................................................................................................................................................................................................................................................................................................................................... 7076
8.2 Galvanised body parts......................................................................................................................................................................................................................................................................................................................................................................................................................................... 7077
8.3 Joining techniques............................................................................................................................................................................................................................................................................................................................................................................................................................................ 7078
8.4 Joining techniques............................................................................................................................................................................................................................................................................................................................................................................................................................................ 7079
9 Plastic repair techniques........................................................................................................................................................................................................................................................................................................................................................................................................................................... 7081
9.1 Plastic repair set............................................................................................................................................................................................................................................................................................................................................................................................................................................ 7081
9.2 Repairing dents............................................................................................................................................................................................................................................................................................................................................................................................................................................... 7082
9.3 Repairing scratches........................................................................................................................................................................................................................................................................................................................................................................................................................................... 7084
9.4 Repairing cracks and tears (up to a length of 100 mm)......................................................................................................................................................................................................................................................................................................................................................................................................... 7085
9.5 Repairing holes (up to 30 mm diameter)........................................................................................................................................................................................................................................................................................................................................................................................................................ 7086
9.6 Plastic repairs (glass fibre materials)....................................................................................................................................................................................................................................................................................................................................................................................................................... 7087
10 Glass repairs...................................................................................................................................................................................................................................................................................................................................................................................................................................................... 7090
10.1 Repairing windscreens........................................................................................................................................................................................................................................................................................................................................................................................................................................ 7090
10.2 Requirements................................................................................................................................................................................................................................................................................................................................................................................................................................................. 7090
10.3 Special tools................................................................................................................................................................................................................................................................................................................................................................................................................................................ 7091
10.4 Description of repair work................................................................................................................................................................................................................................................................................................................................................................................................................................... 7092
11 Aluminium ......................................................................................................................................................................................................................................................................................................................................................................................................................................................... 7095
11.1 Aluminium repairs............................................................................................................................................................................................................................................................................................................................................................................................................................................ 7095
11.2 Surface treatment............................................................................................................................................................................................................................................................................................................................................................................................................................................ 7095
11.3 Removing dents............................................................................................................................................................................................................................................................................................................................................................................................................................................... 7095
12 The Audi Space Frame concept....................................................................................................................................................................................................................................................................................................................................................................................................................................... 7097
13 Contact corrosion.................................................................................................................................................................................................................................................................................................................................................................................................................................................. 7098
14 Threads............................................................................................................................................................................................................................................................................................................................................................................................................................................................ 7099
15 Studs.............................................................................................................................................................................................................................................................................................................................................................................................................................................................. 7100
16 Paintwork.......................................................................................................................................................................................................................................................................................................................................................................................................................................................... 7101
17 Replacement parts.................................................................................................................................................................................................................................................................................................................................................................................................................................................. 7102
18 Safety notes....................................................................................................................................................................................................................................................................................................................................................................................................................................................... 7103
19 Surface treatment.................................................................................................................................................................................................................................................................................................................................................................................................................................................. 7104
20 Cutting............................................................................................................................................................................................................................................................................................................................................................................................................................................................ 7105
21 Removing dents..................................................................................................................................................................................................................................................................................................................................................................................................................................................... 7106
22 Re-forming......................................................................................................................................................................................................................................................................................................................................................................................................................................................... 7107
23 Temperature monitoring during heating.............................................................................................................................................................................................................................................................................................................................................................................................................................. 7108
24 Flanging........................................................................................................................................................................................................................................................................................................................................................................................................................................................... 7109
25 Welding repairs.................................................................................................................................................................................................................................................................................................................................................................................................................................................... 7110
26 Extruded section................................................................................................................................................................................................................................................................................................................................................................................................................................................... 7111
27 Sheet metal panel.................................................................................................................................................................................................................................................................................................................................................................................................................................................. 7112
28 Plug welding....................................................................................................................................................................................................................................................................................................................................................................................................................................................... 7113
29 Welding aluminium.................................................................................................................................................................................................................................................................................................................................................................................................................................................. 7114
30 Checking weld seams and aluminium node castings.................................................................................................................................................................................................................................................................................................................................................................................................................... 7115
31 Laser weld seam.................................................................................................................................................................................................................................................................................................................................................................................................................................................... 7116
32 Overview of rivets and tools....................................................................................................................................................................................................................................................................................................................................................................................................................................... 7117
33 Riveting repairs................................................................................................................................................................................................................................................................................................................................................................................................................................................... 7118
34 Clinching.......................................................................................................................................................................................................................................................................................................................................................................................................................................................... 7119
35 Solid rivet........................................................................................................................................................................................................................................................................................................................................................................................................................................................ 7120
36 Pop rivet.......................................................................................................................................................................................................................................................................................................................................................................................................................................................... 7121
37 Fitting solid rivets............................................................................................................................................................................................................................................................................................................................................................................................................................................... 7122
38 Fitting punch rivets............................................................................................................................................................................................................................................................................................................................................................................................................................................... 7123
39 Fitting pop rivets................................................................................................................................................................................................................................................................................................................................................................................................................................................. 7124
40 Incorrect riveting................................................................................................................................................................................................................................................................................................................................................................................................................................................. 7125
41 Joddling........................................................................................................................................................................................................................................................................................................................................................................................................................................................... 7127
42 Placing additional thickness of same material behind joint......................................................................................................................................................................................................................................................................................................................................................................................................... 7128
43 Filling separating cuts............................................................................................................................................................................................................................................................................................................................................................................................................................................ 7129
44 Bonded joint....................................................................................................................................................................................................................................................................................................................................................................................................................................................... 7130
45 Inaccessible rivets................................................................................................................................................................................................................................................................................................................................................................................................................................................ 7132
46 Explanation of symbols............................................................................................................................................................................................................................................................................................................................................................................................................................................. 7133
47 Explanation of symbols for riveting operations..................................................................................................................................................................................................................................................................................................................................................................................................................... 7134
48 Explanation of symbols............................................................................................................................................................................................................................................................................................................................................................................................................................................. 7135
49 Cavity sealing..................................................................................................................................................................................................................................................................................................................................................................................................................................................... 7136
Brake_system.............................................................................................................................................................................................................................................................................................................................................................................................................................................................. 7137
00 – Technical data................................................................................................................................................................................................................................................................................................................................................................................................................................................... 7141
1 Identification.................................................................................................................................................................................................................................................................................................................................................................................................................................................. 7141
1.1 PR number and type of brake system........................................................................................................................................................................................................................................................................................................................................................................................................................ 7141
2 Brake test...................................................................................................................................................................................................................................................................................................................................................................................................................................................... 7144
2.1 General notes............................................................................................................................................................................................................................................................................................................................................................................................................................................. 7144
2.2 Testing vehicles with front-wheel drive................................................................................................................................................................................................................................................................................................................................................................................................................... 7145
2.3 Testing vehicles with four-wheel drive.................................................................................................................................................................................................................................................................................................................................................................................................................... 7145
2.4 Testing parking brake..................................................................................................................................................................................................................................................................................................................................................................................................................................... 7145
2.5 Visible features of ceramic brake disc.................................................................................................................................................................................................................................................................................................................................................................................................................... 7146
2.6 Superficial cracks in cooling channel lands............................................................................................................................................................................................................................................................................................................................................................................................................... 7148
2.7 Cracks in area of bolt connection on ceramic brake discs.................................................................................................................................................................................................................................................................................................................................................................................................. 7148
2.8 Edge fractures............................................................................................................................................................................................................................................................................................................................................................................................................................................ 7149
2.9 Chipping on ceramic brake discs........................................................................................................................................................................................................................................................................................................................................................................................................................... 7149
2.10 Cracks extending into cooling channels................................................................................................................................................................................................................................................................................................................................................................................................................... 7150
2.11 Assessing degree of wear on ceramic brake discs.......................................................................................................................................................................................................................................................................................................................................................................................................... 7150
2.12 Wear assessment by checking thickness of brake disc...................................................................................................................................................................................................................................................................................................................................................................................................... 7154
2.13 Wear assessment by checking thickness of brake disc...................................................................................................................................................................................................................................................................................................................................................................................................... 7154
2.14 Wear assessment according to wear indicators............................................................................................................................................................................................................................................................................................................................................................................................................. 7155
2.15 Weighing brake disc...................................................................................................................................................................................................................................................................................................................................................................................................................................... 7156
45 – Anti-lock brake system........................................................................................................................................................................................................................................................................................................................................................................................................................................... 7158
1 General notes................................................................................................................................................................................................................................................................................................................................................................................................................................................... 7158
1.1 Notes for repair work on the ABS.......................................................................................................................................................................................................................................................................................................................................................................................................................... 7158
1.2 Vehicle diagnostic, testing and information system........................................................................................................................................................................................................................................................................................................................................................................................................ 7159
2 Overview of fitting locations................................................................................................................................................................................................................................................................................................................................................................................................................................... 7161
2.1 Overview of fitting locations - ABS/ESP................................................................................................................................................................................................................................................................................................................................................................................................................... 7161
3 Control unit and hydraulic unit................................................................................................................................................................................................................................................................................................................................................................................................................................. 7166
3.1 Exploded view - control unit and hydraulic unit........................................................................................................................................................................................................................................................................................................................................................................................................... 7166
3.2 Removing and installing ABS control unit -J104-/ABS hydraulic unit -N55-.................................................................................................................................................................................................................................................................................................................................................................................. 7167
4 Sensors......................................................................................................................................................................................................................................................................................................................................................................................................................................................... 7172
4.1 Exploded view - front wheel speed sensor.................................................................................................................................................................................................................................................................................................................................................................................................................. 7172
4.2 Exploded view - rear wheel speed sensor................................................................................................................................................................................................................................................................................................................................................................................................................... 7173
4.3 Removing and installing brake light sensor................................................................................................................................................................................................................................................................................................................................................................................................................ 7173
4.4 Removing and installing parking brake contact switch...................................................................................................................................................................................................................................................................................................................................................................................................... 7177
4.5 Removing and installing ESP sensor unit -G419-............................................................................................................................................................................................................................................................................................................................................................................................................ 7178
4.6 Removing and installing front wheel speed sensor -G45-/-G47-.............................................................................................................................................................................................................................................................................................................................................................................................. 7180
4.7 Removing and installing rear wheel speed sensor -G44-/-G46-............................................................................................................................................................................................................................................................................................................................................................................................... 7180
5 Auto Hold....................................................................................................................................................................................................................................................................................................................................................................................................................................................... 7181
5.1 Description of Auto Hold function......................................................................................................................................................................................................................................................................................................................................................................................................................... 7181
5.2 Removing and installing auto-hold button.................................................................................................................................................................................................................................................................................................................................................................................................................. 7182
46 – Brakes - mechanism............................................................................................................................................................................................................................................................................................................................................................................................................................................... 7183
1 Front brakes.................................................................................................................................................................................................................................................................................................................................................................................................................................................... 7183
1.1 Exploded view - front brakes.............................................................................................................................................................................................................................................................................................................................................................................................................................. 7183
1.1.1 Exploded view - front brakes (1LT, 1LY)............................................................................................................................................................................................................................................................................................................................................................................................................. 7183
1.1.2 Exploded view - front brakes (1LA / 1LB / 1LJ / 1LD / 1ZT + S4 / S5)................................................................................................................................................................................................................................................................................................................................................................................ 7185
1.1.3 Exploded view - front brakes (1LM).................................................................................................................................................................................................................................................................................................................................................................................................................. 7188
1.1.4 Exploded view - front brake, ceramic brakes (1LW)................................................................................................................................................................................................................................................................................................................................................................................................... 7191
1.2 Removing and installing brake pads........................................................................................................................................................................................................................................................................................................................................................................................................................ 7194
1.2.1 Removing and installing brake pads (1LT / 1LY)...................................................................................................................................................................................................................................................................................................................................................................................................... 7194
1.2.2 Removing and installing brake pads (1LA / 1LB / 1LJ / 1LD / 1ZT + S4 / S5).......................................................................................................................................................................................................................................................................................................................................................................... 7198
1.2.3 Removing and installing brake pads (1LM)............................................................................................................................................................................................................................................................................................................................................................................................................ 7206
1.2.4 Removing and installing brake pads for ceramic brakes (1LW)......................................................................................................................................................................................................................................................................................................................................................................................... 7208
1.3 Removing and installing brake caliper..................................................................................................................................................................................................................................................................................................................................................................................................................... 7212
1.3.1 Removing and installing brake caliper (1LT / 1LY)................................................................................................................................................................................................................................................................................................................................................................................................... 7212
1.3.2 Removing and installing brake caliper (1LA / 1LB / 1LJ / 1LD / 1ZT + S4 / S5)....................................................................................................................................................................................................................................................................................................................................................................... 7214
1.3.3 Removing and installing brake caliper (1LM)......................................................................................................................................................................................................................................................................................................................................................................................................... 7216
1.3.4 Removing and installing brake caliper for ceramic brakes (1LW)...................................................................................................................................................................................................................................................................................................................................................................................... 7217
1.4 Renewing brake caliper.................................................................................................................................................................................................................................................................................................................................................................................................................................... 7219
1.4.1 Renewing brake caliper (1LT / 1LY).................................................................................................................................................................................................................................................................................................................................................................................................................. 7219
1.4.2 Renewing brake caliper (1LA / 1LB / 1LJ / 1LD / 1ZT + S4 / S5)...................................................................................................................................................................................................................................................................................................................................................................................... 7223
1.4.3 Renewing brake caliper (1LM)........................................................................................................................................................................................................................................................................................................................................................................................................................ 7228
1.4.4 Renewing brake caliper for ceramic brakes (1LW)..................................................................................................................................................................................................................................................................................................................................................................................................... 7230
1.5 Removing and installing brake disc........................................................................................................................................................................................................................................................................................................................................................................................................................ 7231
1.5.1 Removing and installing brake disc (1LT / 1LY)...................................................................................................................................................................................................................................................................................................................................................................................................... 7231
1.5.2 Removing and installing brake disc (1LA / 1LB / 1LJ / 1LD / 1ZT + S4 / S5).......................................................................................................................................................................................................................................................................................................................................................................... 7232
1.5.3 Removing and installing brake disc (1LM)............................................................................................................................................................................................................................................................................................................................................................................................................ 7234
1.5.4 Removing and installing brake disc for ceramic brakes (1LW)......................................................................................................................................................................................................................................................................................................................................................................................... 7235
1.6 Renewing brake disc....................................................................................................................................................................................................................................................................................................................................................................................................................................... 7237
1.6.1 Renewing brake disc (1LT / 1LY)..................................................................................................................................................................................................................................................................................................................................................................................................................... 7237
1.6.2 Renewing brake disc (1LA / 1LB / 1LJ / 1LD / 1ZT + S4 / S5)......................................................................................................................................................................................................................................................................................................................................................................................... 7240
1.6.3 Renewing brake disc (1LM)........................................................................................................................................................................................................................................................................................................................................................................................................................... 7244
1.6.4 Renewing brake disc for ceramic brakes (1LW)........................................................................................................................................................................................................................................................................................................................................................................................................ 7245
1.7 Removing and installing splash plate...................................................................................................................................................................................................................................................................................................................................................................................................................... 7247
1.7.1 Removing and installing splash plate (1LT / 1LY).................................................................................................................................................................................................................................................................................................................................................................................................... 7247
1.7.2 Removing and installing splash plate (1LA / 1LB / 1LJ / 1LD / 1ZT + S4 / S5)........................................................................................................................................................................................................................................................................................................................................................................ 7248
1.7.3 Removing and installing splash plate (1LM).......................................................................................................................................................................................................................................................................................................................................................................................................... 7249
1.7.4 Removing and installing splash plate for ceramic brakes (1LW)....................................................................................................................................................................................................................................................................................................................................................................................... 7250
1.8 Detaching and attaching damper spring..................................................................................................................................................................................................................................................................................................................................................................................................................... 7252
2 Rear brakes..................................................................................................................................................................................................................................................................................................................................................................................................................................................... 7253
2.1 Exploded view - rear brake................................................................................................................................................................................................................................................................................................................................................................................................................................ 7253
2.2 Removing and installing brake pads........................................................................................................................................................................................................................................................................................................................................................................................................................ 7255
2.3 Removing and installing brake caliper..................................................................................................................................................................................................................................................................................................................................................................................................................... 7258
2.4 Renewing brake caliper.................................................................................................................................................................................................................................................................................................................................................................................................................................... 7261
2.5 Removing and installing brake disc........................................................................................................................................................................................................................................................................................................................................................................................................................ 7264
2.6 Renewing brake disc....................................................................................................................................................................................................................................................................................................................................................................................................................................... 7265
2.7 Removing and installing splash plate...................................................................................................................................................................................................................................................................................................................................................................................................................... 7267
2.8 Removing and installing splash plate, front-wheel drive vehicles.......................................................................................................................................................................................................................................................................................................................................................................................... 7268
3 Parking brake................................................................................................................................................................................................................................................................................................................................................................................................................................................... 7269
3.1 Overview of fitting locations - parking brake............................................................................................................................................................................................................................................................................................................................................................................................................. 7269
3.2 Removing and installing control unit for electromechanical parking brake -J540-........................................................................................................................................................................................................................................................................................................................................................................... 7270
3.3 Removing and installing parking brake motor -V282-/ -V283-................................................................................................................................................................................................................................................................................................................................................................................................ 7271
4 Brake pedal..................................................................................................................................................................................................................................................................................................................................................................................................................................................... 7275
4.1 Exploded view - brake pedal............................................................................................................................................................................................................................................................................................................................................................................................................................... 7275
4.2 Removing and installing mounting bracket.................................................................................................................................................................................................................................................................................................................................................................................................................. 7277
4.2.1 Removing and installing mounting bracket, vehicles with manual gearbox.............................................................................................................................................................................................................................................................................................................................................................................. 7277
4.2.2 Removing and installing mounting bracket, vehicles with automatic gearbox........................................................................................................................................................................................................................................................................................................................................................................... 7288
4.3 Separating brake pedal from brake servo................................................................................................................................................................................................................................................................................................................................................................................................................... 7297
4.4 Connecting brake pedal to brake servo..................................................................................................................................................................................................................................................................................................................................................................................................................... 7299
4.5 Removing and installing brake pedal....................................................................................................................................................................................................................................................................................................................................................................................................................... 7301
4.5.1 Removing and installing brake pedal, vehicles with manual gearbox................................................................................................................................................................................................................................................................................................................................................................................... 7301
4.5.2 Removing and installing brake pedal, vehicles with automatic gearbox................................................................................................................................................................................................................................................................................................................................................................................ 7303
4.6 Removing and installing mounting for brake servo push rod................................................................................................................................................................................................................................................................................................................................................................................................. 7308
47 – Brakes - hydraulics.............................................................................................................................................................................................................................................................................................................................................................................................................................................. 7313
1 Front brake caliper............................................................................................................................................................................................................................................................................................................................................................................................................................................. 7313
1.1 Exploded view - front brake caliper....................................................................................................................................................................................................................................................................................................................................................................................................................... 7313
1.1.1 Exploded view - front brake caliper (FN3 / 1LT)..................................................................................................................................................................................................................................................................................................................................................................................................... 7313
1.1.2 Exploded view - front brake caliper (FBC / 1LA / 1LJ)............................................................................................................................................................................................................................................................................................................................................................................................... 7315
1.1.3 Exploded view - front brake caliper for ceramic brakes (1LW)........................................................................................................................................................................................................................................................................................................................................................................................ 7316
1.2 Removing and installing brake caliper pistons............................................................................................................................................................................................................................................................................................................................................................................................................. 7317
1.2.1 Removing and installing brake caliper piston (1LT).................................................................................................................................................................................................................................................................................................................................................................................................. 7317
1.2.2 Removing and installing brake caliper piston (1LA / 1LJ)............................................................................................................................................................................................................................................................................................................................................................................................ 7319
1.2.3 Removing and installing brake caliper pistons for ceramic brakes (1LW).............................................................................................................................................................................................................................................................................................................................................................................. 7321
1.3 Renewing bearing bushes and guide pins.................................................................................................................................................................................................................................................................................................................................................................................................................... 7323
1.3.1 Renewing bearing bushes and guide pins (1LT)........................................................................................................................................................................................................................................................................................................................................................................................................ 7323
1.3.2 Renewing bearing bushes and guide pins (FBC / 1LA / 1LJ)............................................................................................................................................................................................................................................................................................................................................................................................ 7324
2 Rear brake caliper.............................................................................................................................................................................................................................................................................................................................................................................................................................................. 7328
2.1 Exploded view - rear brake caliper........................................................................................................................................................................................................................................................................................................................................................................................................................ 7328
2.2 Removing and installing brake caliper piston.............................................................................................................................................................................................................................................................................................................................................................................................................. 7329
2.3 Renewing bearing bushes and guide pins.................................................................................................................................................................................................................................................................................................................................................................................................................... 7332
3 Brake servo / brake master cylinder............................................................................................................................................................................................................................................................................................................................................................................................................................. 7334
3.1 Exploded view - brake servo / brake master cylinder....................................................................................................................................................................................................................................................................................................................................................................................................... 7334
3.2 Removing and installing brake servo....................................................................................................................................................................................................................................................................................................................................................................................................................... 7336
3.3 Removing and installing brake master cylinder............................................................................................................................................................................................................................................................................................................................................................................................................. 7340
3.4 Removing and installing brake fluid reservoir............................................................................................................................................................................................................................................................................................................................................................................................................. 7343
3.5 Removing and installing cover for brake fluid reservoir................................................................................................................................................................................................................................................................................................................................................................................................... 7345
4 Vacuum system................................................................................................................................................................................................................................................................................................................................................................................................................................................... 7348
4.1 Exploded view - electric vacuum pump...................................................................................................................................................................................................................................................................................................................................................................................................................... 7348
4.1.1 Exploded view - electric vacuum pump (all vehicles except RS 5)..................................................................................................................................................................................................................................................................................................................................................................................... 7348
4.1.2 Exploded view - electric vacuum pump (RS 5)......................................................................................................................................................................................................................................................................................................................................................................................................... 7349
4.2 Exploded view - vacuum pump............................................................................................................................................................................................................................................................................................................................................................................................................................... 7351
4.3 Checking non-return valve................................................................................................................................................................................................................................................................................................................................................................................................................................. 7352
4.3.1 Checking non-return valve (all vehicles except RS 5)................................................................................................................................................................................................................................................................................................................................................................................................ 7352
4.3.2 Checking non-return valve (RS 5).................................................................................................................................................................................................................................................................................................................................................................................................................... 7352
4.4 Removing and installing non-return valve.................................................................................................................................................................................................................................................................................................................................................................................................................. 7352
4.4.1 Removing and installing non-return valve (all vehicles except RS 5)................................................................................................................................................................................................................................................................................................................................................................................. 7352
4.4.2 Removing and installing non-return valve (RS 5)..................................................................................................................................................................................................................................................................................................................................................................................................... 7353
4.5 Removing and installing brake servo pressure sensor....................................................................................................................................................................................................................................................................................................................................................................................................... 7354
4.6 Checking vacuum system.................................................................................................................................................................................................................................................................................................................................................................................................................................... 7355
4.6.1 Checking vacuum system (all vehicles except RS 5)................................................................................................................................................................................................................................................................................................................................................................................................... 7355
4.6.2 Checking vacuum system (RS 5)....................................................................................................................................................................................................................................................................................................................................................................................................................... 7356
4.7 Removing and installing electric vacuum pump for brakes................................................................................................................................................................................................................................................................................................................................................................................................... 7357
4.7.1 Removing and installing electric vacuum pump for brakes (all vehicles except RS 5).................................................................................................................................................................................................................................................................................................................................................................. 7357
4.7.2 Removing and installing electric vacuum pump for brakes (RS 5)...................................................................................................................................................................................................................................................................................................................................................................................... 7359
4.8 Removing and installing bracket for electric vacuum pump.................................................................................................................................................................................................................................................................................................................................................................................................. 7362
4.8.1 Removing and installing bracket for electric vacuum pump (all vehicles except RS 5)................................................................................................................................................................................................................................................................................................................................................................. 7362
4.8.2 Removing and installing bracket for electric vacuum pump (RS 5)..................................................................................................................................................................................................................................................................................................................................................................................... 7363
4.9 Removing and installing vacuum pump....................................................................................................................................................................................................................................................................................................................................................................................................................... 7364
4.9.1 Removing and installing vacuum pump (2.7 ltr. TDI and 3.0 ltr. TDI diesel engine)................................................................................................................................................................................................................................................................................................................................................................... 7364
4.9.2 Removing and installing vacuum pump (2.0 ltr. TDI engine)........................................................................................................................................................................................................................................................................................................................................................................................... 7366
4.9.3 Removing and installing vacuum pump (4-cyl. turbo FSI engine)....................................................................................................................................................................................................................................................................................................................................................................................... 7368
4.9.4 Removing and installing vacuum pump (V6 FSI)........................................................................................................................................................................................................................................................................................................................................................................................................ 7370
4.9.5 Removing and installing vacuum pump (V6 TFSI)....................................................................................................................................................................................................................................................................................................................................................................................................... 7371
5 Brake lines..................................................................................................................................................................................................................................................................................................................................................................................................................................................... 7372
5.1 Routing of brake lines.................................................................................................................................................................................................................................................................................................................................................................................................................................... 7372
6 Hydraulic system................................................................................................................................................................................................................................................................................................................................................................................................................................................ 7374
6.1 General notes on brake fluid.............................................................................................................................................................................................................................................................................................................................................................................................................................. 7374
6.2 Bleeding hydraulic system (normal bleeding procedure)..................................................................................................................................................................................................................................................................................................................................................................................................... 7375
6.3 Leak test................................................................................................................................................................................................................................................................................................................................................................................................................................................. 7376
6.4 High-pressure and low-pressure tests...................................................................................................................................................................................................................................................................................................................................................................................................................... 7377
Communication............................................................................................................................................................................................................................................................................................................................................................................................................................................................. 7379
91 – Radio, telephone, navigation..................................................................................................................................................................................................................................................................................................................................................................................................................................... 7383
1 Infotainment system............................................................................................................................................................................................................................................................................................................................................................................................................................................. 7383
1.1 Layout - infotainment system.............................................................................................................................................................................................................................................................................................................................................................................................................................. 7383
1.1.1 Layout - infotainment system, up to week 44/2008.................................................................................................................................................................................................................................................................................................................................................................................................... 7383
1.1.2 Layout - infotainment system, from week 45/2008 onwards............................................................................................................................................................................................................................................................................................................................................................................................. 7387
1.1.3 Layout - infotainment system, USA, up to week 44/2008............................................................................................................................................................................................................................................................................................................................................................................................... 7393
1.1.4 Layout - infotainment system, USA, from week 45/2008 onwards........................................................................................................................................................................................................................................................................................................................................................................................ 7395
1.1.5 Layout - infotainment system, Japan, up to week 44/2008............................................................................................................................................................................................................................................................................................................................................................................................. 7400
1.1.6 Layout - infotainment system, Japan, from week 45/2008 onwards...................................................................................................................................................................................................................................................................................................................................................................................... 7402
1.2 Overview of fitting locations - infotainment system....................................................................................................................................................................................................................................................................................................................................................................................................... 7407
1.2.1 Overview of fitting locations - infotainment system, basic/basic plus navigation system............................................................................................................................................................................................................................................................................................................................................................. 7407
1.2.2 Overview of fitting locations - infotainment system, up to week 44/2008............................................................................................................................................................................................................................................................................................................................................................................. 7408
1.2.3 Overview of fitting locations - infotainment system, from week 45/2008 onwards...................................................................................................................................................................................................................................................................................................................................................................... 7409
1.2.4 Overview of fitting locations - infotainment system, USA, up to week 44/2008........................................................................................................................................................................................................................................................................................................................................................................ 7410
1.2.5 Overview of fitting locations - infotainment system, USA, from week 45/2008 onwards................................................................................................................................................................................................................................................................................................................................................................. 7411
1.2.6 Overview of fitting locations - infotainment system, Japan, up to week 44/2008...................................................................................................................................................................................................................................................................................................................................................................... 7412
1.2.7 Overview of fitting locations - infotainment system, Japan, from week 45/2008 onwards............................................................................................................................................................................................................................................................................................................................................................... 7413
1.3 Removing and installing infotainment system display....................................................................................................................................................................................................................................................................................................................................................................................................... 7414
1.4 Removing and installing control unit for front display and information control panel...................................................................................................................................................................................................................................................................................................................................................................... 7414
1.4.1 Removing and installing control unit for front display and information control panel -J523-, MMI basic.............................................................................................................................................................................................................................................................................................................................................. 7414
1.4.2 Removing and installing control unit for front display and information control panel -J523-, up to week 44/2008..................................................................................................................................................................................................................................................................................................................................... 7415
1.5 Removing and installing control unit 1 for information electronics -J794-................................................................................................................................................................................................................................................................................................................................................................................. 7417
1.6 Removing and installing multimedia system operating unit -E380-........................................................................................................................................................................................................................................................................................................................................................................................... 7418
1.7 Pin assignment............................................................................................................................................................................................................................................................................................................................................................................................................................................ 7420
1.7.7 Pin assignment for MMI basic display................................................................................................................................................................................................................................................................................................................................................................................................................ 7432
1.7.8 Pin assignment for MMI display, up to week 44/2008.................................................................................................................................................................................................................................................................................................................................................................................................. 7433
1.7.10 Pin assignment for multimedia system operating unit -E380-......................................................................................................................................................................................................................................................................................................................................................................................... 7435
1.7.11 Pin assignment for display, radio.................................................................................................................................................................................................................................................................................................................................................................................................................. 7435
2 Sound system.................................................................................................................................................................................................................................................................................................................................................................................................................................................... 7436
2.1 Layout - sound system..................................................................................................................................................................................................................................................................................................................................................................................................................................... 7436
2.2 Overview of fitting locations - sound system.............................................................................................................................................................................................................................................................................................................................................................................................................. 7443
2.2.1 Overview of fitting locations - sound system, up to week 44/2008.................................................................................................................................................................................................................................................................................................................................................................................... 7443
2.2.2 Overview of fitting locations - sound system, Coupé, from week 45/2008 onwards...................................................................................................................................................................................................................................................................................................................................................................... 7445
2.2.3 Overview of fitting locations - sound system, Sportback............................................................................................................................................................................................................................................................................................................................................................................................. 7447
2.3 Removing and installing digital sound package control unit/amplifier...................................................................................................................................................................................................................................................................................................................................................................................... 7448
2.3.1 Removing and installing digital sound package control unit -J525- (CAN)............................................................................................................................................................................................................................................................................................................................................................................. 7448
2.3.2 Removing and installing digital sound package control unit -J525-, MMI, up to week 44/2008.......................................................................................................................................................................................................................................................................................................................................................... 7449
2.3.3 Removing and installing digital sound package control unit -J525-, MMI, from week 45/2008 onwards................................................................................................................................................................................................................................................................................................................................................... 7450
2.4 Removing and installing rear treble loudspeakers -R14-/-R16-.............................................................................................................................................................................................................................................................................................................................................................................................. 7451
2.4.1 Removing and installing rear treble loudspeaker (Coupé)............................................................................................................................................................................................................................................................................................................................................................................................. 7451
2.4.2 Removing and installing rear treble loudspeakers, Sportback......................................................................................................................................................................................................................................................................................................................................................................................... 7452
2.5 Removing and installing front treble loudspeakers -R20-/-R22-............................................................................................................................................................................................................................................................................................................................................................................................. 7452
2.5.1 Removing and installing front treble loudspeaker, B+O............................................................................................................................................................................................................................................................................................................................................................................................... 7452
2.5.2 Removing and installing front treble loudspeakers................................................................................................................................................................................................................................................................................................................................................................................................... 7453
2.6 Removing and installing rear mid-range loudspeaker........................................................................................................................................................................................................................................................................................................................................................................................................ 7454
2.6.1 Removing and installing rear mid-range loudspeaker, Coupé........................................................................................................................................................................................................................................................................................................................................................................................... 7454
2.6.2 Removing and installing rear mid-range loudspeakers, Sportback...................................................................................................................................................................................................................................................................................................................................................................................... 7454
2.7 Removing and installing front mid-range loudspeakers...................................................................................................................................................................................................................................................................................................................................................................................................... 7455
2.7.1 Removing and installing front mid-range loudspeaker, B+O............................................................................................................................................................................................................................................................................................................................................................................................ 7455
2.8 Removing and installing rear mid-range and bass loudspeakers.............................................................................................................................................................................................................................................................................................................................................................................................. 7456
2.8.1 Removing and installing rear mid-range and bass loudspeaker (Coupé)................................................................................................................................................................................................................................................................................................................................................................................. 7456
2.8.2 Removing and installing rear mid-range and bass loudspeakers, Sportback............................................................................................................................................................................................................................................................................................................................................................................. 7456
2.9 Removing and installing front bass loudspeakers -R21-/-R23-............................................................................................................................................................................................................................................................................................................................................................................................... 7457
2.9.1 Removing and installing front mid-range and bass loudspeaker/ bass loudspeaker...................................................................................................................................................................................................................................................................................................................................................................... 7457
2.10 Removing and installing subwoofer -R211-................................................................................................................................................................................................................................................................................................................................................................................................................. 7458
2.10.1 Removing and installing subwoofer in rear shelf -R157-, Coupé...................................................................................................................................................................................................................................................................................................................................................................................... 7458
2.10.2 Removing and installing subwoofer in rear shelf -R157-, Sportback.................................................................................................................................................................................................................................................................................................................................................................................. 7458
2.11 Removing and installing centre loudspeaker............................................................................................................................................................................................................................................................................................................................................................................................................... 7459
2.11.1 Removing and installing centre mid-range and treble loudspeaker -R158-............................................................................................................................................................................................................................................................................................................................................................................. 7459
2.12 Pin assignment........................................................................................................................................................................................................................................................................................................................................................................................................................................... 7460
3 Aerial systems.................................................................................................................................................................................................................................................................................................................................................................................................................................................. 7468
3.1 Layout - aerial systems................................................................................................................................................................................................................................................................................................................................................................................................................................... 7468
3.1.1 Layout - aerial systems, Coupé...................................................................................................................................................................................................................................................................................................................................................................................................................... 7468
3.1.2 Layout - aerial systems, Sportback.................................................................................................................................................................................................................................................................................................................................................................................................................. 7469
3.2 Overview of fitting locations - aerial systems............................................................................................................................................................................................................................................................................................................................................................................................................ 7469
3.2.1 Overview of fitting locations - aerial systems, Coupé............................................................................................................................................................................................................................................................................................................................................................................................... 7469
3.2.2 Overview of fitting locations - aerial systems, Sportback........................................................................................................................................................................................................................................................................................................................................................................................... 7471
3.3 Removing and installing aerial amplifiers................................................................................................................................................................................................................................................................................................................................................................................................................. 7472
3.3.1 Removing and installing aerial amplifier -R111-/-R112-, Coupé....................................................................................................................................................................................................................................................................................................................................................................................... 7472
3.3.2 Removing and installing aerial amplifier -R24-/-R112-, Sportback.................................................................................................................................................................................................................................................................................................................................................................................... 7472
3.3.3 Removing and installing aerial amplifier 2 -R111-, Sportback........................................................................................................................................................................................................................................................................................................................................................................................ 7473
3.3.4 Removing and installing aerial amplifier 4 -R113-, Sportback........................................................................................................................................................................................................................................................................................................................................................................................ 7473
3.4 Removing and installing traffic data aerial............................................................................................................................................................................................................................................................................................................................................................................................................... 7474
3.5 Removing and installing roof aerial....................................................................................................................................................................................................................................................................................................................................................................................................................... 7475
3.5.1 Removing and installing roof aerial, Coupé.......................................................................................................................................................................................................................................................................................................................................................................................................... 7475
3.5.2 Removing and installing roof aerial -R216-, Sportback............................................................................................................................................................................................................................................................................................................................................................................................... 7475
3.6 Removing and installing internet access aerial............................................................................................................................................................................................................................................................................................................................................................................................................ 7476
3.7 Pin assignment for aerial amplifier....................................................................................................................................................................................................................................................................................................................................................................................................................... 7476
3.7.1 Pin assignment for aerial amplifier, Coupé.......................................................................................................................................................................................................................................................................................................................................................................................................... 7476
3.7.2 Pin assignment for aerial amplifier, Sportback...................................................................................................................................................................................................................................................................................................................................................................................................... 7481
4 Radio........................................................................................................................................................................................................................................................................................................................................................................................................................................................... 7486
4.1 Layout - radio............................................................................................................................................................................................................................................................................................................................................................................................................................................ 7486
4.1.1 Layout - radio...................................................................................................................................................................................................................................................................................................................................................................................................................................... 7486
4.1.2 Layout - radio (USA)................................................................................................................................................................................................................................................................................................................................................................................................................................ 7487
4.2 Overview of fitting locations - radio..................................................................................................................................................................................................................................................................................................................................................................................................................... 7488
4.3 Removing and installing radio............................................................................................................................................................................................................................................................................................................................................................................................................................. 7489
4.3.1 Removing and installing radio -R-................................................................................................................................................................................................................................................................................................................................................................................................................... 7489
4.3.2 Removing and installing radio -R-, MMI, up to week 44/2008.......................................................................................................................................................................................................................................................................................................................................................................................... 7490
4.3.3 Removing and installing radio -R-, MMI, from week 45/2008 onwards................................................................................................................................................................................................................................................................................................................................................................................... 7491
4.3.4 Removing and installing digital radio -R147-, up to week 44/2008.................................................................................................................................................................................................................................................................................................................................................................................... 7493
4.3.5 Removing and installing satellite radio -R146-, USA, up to week 44/2008............................................................................................................................................................................................................................................................................................................................................................................. 7494
4.4 Pin assignment............................................................................................................................................................................................................................................................................................................................................................................................................................................ 7496
4.4.1 Pin assignment for radio chorus..................................................................................................................................................................................................................................................................................................................................................................................................................... 7496
4.4.2 Pin assignment for radio concert/symphony........................................................................................................................................................................................................................................................................................................................................................................................................... 7498
4.4.3 Pin assignment for radio symphony, USA.............................................................................................................................................................................................................................................................................................................................................................................................................. 7500
5 DVD/CD changer.................................................................................................................................................................................................................................................................................................................................................................................................................................................. 7512
5.1 Pin assignment............................................................................................................................................................................................................................................................................................................................................................................................................................................ 7512
5.2 Removing and installing CD changer........................................................................................................................................................................................................................................................................................................................................................................................................................ 7512
5.2.1 Removing and installing CD changer -R41-, up to week 44/2008........................................................................................................................................................................................................................................................................................................................................................................................ 7512
5.2.2 Removing and installing CD changer -R41-, from week 45/2008 onwards................................................................................................................................................................................................................................................................................................................................................................................. 7514
6 Telephone system................................................................................................................................................................................................................................................................................................................................................................................................................................................ 7516
6.1 Layout - telephone........................................................................................................................................................................................................................................................................................................................................................................................................................................ 7516
6.1.1 Layout - telephone, up to week 44/2008.............................................................................................................................................................................................................................................................................................................................................................................................................. 7516
6.1.2 Layout - telephone, from week 45/2008 onwards....................................................................................................................................................................................................................................................................................................................................................................................................... 7519
6.1.3 Layout - telephone, USA, up to week 44/2008......................................................................................................................................................................................................................................................................................................................................................................................................... 7525
6.1.4 Layout - telephone, USA, from week 45/2008 onwards.................................................................................................................................................................................................................................................................................................................................................................................................. 7527
6.1.5 Layout - telephone, Japan, up to week 44/2008....................................................................................................................................................................................................................................................................................................................................................................................................... 7531
6.1.6 Layout - telephone, Japan, from week 45/2008 onwards................................................................................................................................................................................................................................................................................................................................................................................................ 7533
6.2 Overview of fitting locations - telephone system.......................................................................................................................................................................................................................................................................................................................................................................................................... 7535
6.2.1 Overview of fitting locations - telephone system, up to week 44/2008................................................................................................................................................................................................................................................................................................................................................................................ 7535
6.2.2 Overview of fitting locations - telephone system, from week 45/2008 onwards......................................................................................................................................................................................................................................................................................................................................................................... 7536
6.2.3 Overview of fitting locations - telephone system, USA, up to week 44/2008........................................................................................................................................................................................................................................................................................................................................................................... 7537
6.2.4 Overview of fitting locations - telephone system, USA, from week 45/2008 onwards.................................................................................................................................................................................................................................................................................................................................................................... 7538
6.2.5 Overview of fitting locations - telephone system, Japan, up to week 44/2008......................................................................................................................................................................................................................................................................................................................................................................... 7539
6.2.6 Overview of fitting locations - telephone system, Japan, from week 45/2008 onwards.................................................................................................................................................................................................................................................................................................................................................................. 7540
6.3 Exploded view - microphone unit........................................................................................................................................................................................................................................................................................................................................................................................................................... 7540
6.3.1 Microphone unit in front roof module -R164-, up to week 44/2008..................................................................................................................................................................................................................................................................................................................................................................................... 7540
6.3.2 Microphone unit in front roof module -R164-, from week 45/2008 onwards.............................................................................................................................................................................................................................................................................................................................................................................. 7541
6.4 Removing and installing microphone unit in front roof module -R164-....................................................................................................................................................................................................................................................................................................................................................................................... 7542
6.5 Removing and installing aerial amplifier for mobile telephone -R86-....................................................................................................................................................................................................................................................................................................................................................................................... 7543
6.6 Removing and installing telephone bracket -R126-.......................................................................................................................................................................................................................................................................................................................................................................................................... 7544
6.6.1 Removing and installing telephone bracket -R126- (mobile telephone retainer)........................................................................................................................................................................................................................................................................................................................................................................ 7544
6.6.2 Removing and installing telephone bracket -R126- (handset cradle)................................................................................................................................................................................................................................................................................................................................................................................... 7544
6.6.3 Removing and installing connecting wiring, mobile telephone retainer, Japan, up to week 44/2008..................................................................................................................................................................................................................................................................................................................................................... 7545
6.7 Removing and installing telephone transmitter and receiver unit........................................................................................................................................................................................................................................................................................................................................................................................... 7545
6.8 Pin assignment............................................................................................................................................................................................................................................................................................................................................................................................................................................ 7548
6.8.10 Pin assignment for pre-fitted components for mobile phone installation............................................................................................................................................................................................................................................................................................................................................................................. 7561
6.8.15 Pin assignment for mobile phone pre-installation, Japan, up to week 44/2008........................................................................................................................................................................................................................................................................................................................................................................ 7565
7 Navigation system............................................................................................................................................................................................................................................................................................................................................................................................................................................... 7566
7.1 Layout - navigation system................................................................................................................................................................................................................................................................................................................................................................................................................................ 7566
7.1.1 Layout - navigation system, up to week 44/2008...................................................................................................................................................................................................................................................................................................................................................................................................... 7566
7.1.2 Layout - navigation system, from week 45/2008 onwards............................................................................................................................................................................................................................................................................................................................................................................................... 7568
7.1.3 Layout - navigation system, Japan, up to week 44/2008............................................................................................................................................................................................................................................................................................................................................................................................... 7570
7.1.4 Layout - navigation system, Japan, from week 45/2008 onwards........................................................................................................................................................................................................................................................................................................................................................................................ 7571
7.2 Overview of fitting locations - navigation system......................................................................................................................................................................................................................................................................................................................................................................................................... 7573
7.2.1 Overview of fitting locations - navigation system, up to week 44/2008............................................................................................................................................................................................................................................................................................................................................................................... 7573
7.2.2 Overview of fitting locations - navigation system, from week 45/2008 onwards........................................................................................................................................................................................................................................................................................................................................................................ 7574
7.2.3 Overview of fitting locations - navigation system, Japan, up to week 44/2008........................................................................................................................................................................................................................................................................................................................................................................ 7575
7.2.4 Overview of fitting locations - navigation system, Japan, from week 45/2008 onwards................................................................................................................................................................................................................................................................................................................................................................. 7576
7.3 Pin assignment............................................................................................................................................................................................................................................................................................................................................................................................................................................ 7577
7.3.6 Pin assignment for chip card reader control unit -J676-, Japan, up to week 44/2008.................................................................................................................................................................................................................................................................................................................................................................. 7587
7.3.7 Pin assignment for chip card reader control unit -J676-, Japan, from week 45/2008 onwards........................................................................................................................................................................................................................................................................................................................................................... 7587
7.4 Removing and installing control unit for navigation system................................................................................................................................................................................................................................................................................................................................................................................................ 7588
7.4.1 Removing and installing navigation system with CD drive control unit -J401-, basic plus............................................................................................................................................................................................................................................................................................................................................................. 7588
7.4.2 Removing and installing navigation system with CD drive control unit -J401-, MMI, up to week 44/2008................................................................................................................................................................................................................................................................................................................................................ 7589
7.5 Removing and installing chip card reader control unit..................................................................................................................................................................................................................................................................................................................................................................................................... 7591
8 TV system....................................................................................................................................................................................................................................................................................................................................................................................................................................................... 7592
8.1 Layout - TV system........................................................................................................................................................................................................................................................................................................................................................................................................................................ 7592
8.1.1 Layout - TV system.................................................................................................................................................................................................................................................................................................................................................................................................................................. 7592
8.1.2 Layout - TV system (Japan).......................................................................................................................................................................................................................................................................................................................................................................................................................... 7595
8.2 Overview of fitting locations - TV system................................................................................................................................................................................................................................................................................................................................................................................................................. 7598
8.2.1 Overview of fitting locations - TV system, up to week 44/2008....................................................................................................................................................................................................................................................................................................................................................................................... 7598
8.2.2 Overview of fitting locations - TV system, from week 45/2008 onwards................................................................................................................................................................................................................................................................................................................................................................................ 7599
8.2.3 Overview of fitting locations - TV system, Japan, up to week 44/2008................................................................................................................................................................................................................................................................................................................................................................................ 7600
8.2.4 Overview of fitting locations - TV system, Japan, from week 45/2008 onwards......................................................................................................................................................................................................................................................................................................................................................................... 7601
8.3 Pin assignment............................................................................................................................................................................................................................................................................................................................................................................................................................................ 7602
8.4 Removing and installing TV tuner.......................................................................................................................................................................................................................................................................................................................................................................................................................... 7608
8.4.1 Removing and installing TV tuner -R78-, up to week 44/2008.......................................................................................................................................................................................................................................................................................................................................................................................... 7608
8.4.2 Removing and installing TV tuner -R78-, from week 45/2008 onwards................................................................................................................................................................................................................................................................................................................................................................................... 7609
8.4.3 Removing and installing TV tuner -R78-, from model year 2012 onwards................................................................................................................................................................................................................................................................................................................................................................................ 7611
8.5 Removing and installing TV card reader.................................................................................................................................................................................................................................................................................................................................................................................................................... 7613
8.5.1 Removing and installing TV card reader -R204-, up to week 44/2008................................................................................................................................................................................................................................................................................................................................................................................... 7613
8.5.2 Removing and installing TV card reader -R204-, from week 45/2008 onwards............................................................................................................................................................................................................................................................................................................................................................................ 7613
9 Reversing camera system......................................................................................................................................................................................................................................................................................................................................................................................................................................... 7615
9.1 Layout - reversing camera system.......................................................................................................................................................................................................................................................................................................................................................................................................................... 7615
9.2 Overview of fitting locations - reversing camera system................................................................................................................................................................................................................................................................................................................................................................................................... 7618
9.3 Removing and installing reversing camera -R189-........................................................................................................................................................................................................................................................................................................................................................................................................... 7618
9.3.1 Removing and installing reversing camera -R189-, Coupé.............................................................................................................................................................................................................................................................................................................................................................................................. 7618
9.3.2 Removing and installing reversing camera -R189-, Sportback.......................................................................................................................................................................................................................................................................................................................................................................................... 7619
9.4 Calibrating reversing camera system....................................................................................................................................................................................................................................................................................................................................................................................................................... 7620
9.4.1 Setting up and aligning calibration unit -VAS 6350/4-............................................................................................................................................................................................................................................................................................................................................................................................... 7620
9.4.2 Calibrating reversing camera -R189-................................................................................................................................................................................................................................................................................................................................................................................................................. 7622
9.5 Removing and installing reversing camera system control unit -J772-....................................................................................................................................................................................................................................................................................................................................................................................... 7625
9.5.1 Removing and installing reversing camera system control unit -J772-................................................................................................................................................................................................................................................................................................................................................................................. 7625
9.5.2 Removing and installing reversing camera system control unit -J772-, RS 5........................................................................................................................................................................................................................................................................................................................................................................... 7625
9.6 Connectors on reversing camera system control unit -J772-................................................................................................................................................................................................................................................................................................................................................................................................. 7626
10 Multi-function steering wheel.................................................................................................................................................................................................................................................................................................................................................................................................................................. 7628
10.1 Layout - multi-function steering wheel................................................................................................................................................................................................................................................................................................................................................................................................................... 7628
10.2 Exploded view - multi-function steering wheel............................................................................................................................................................................................................................................................................................................................................................................................................ 7628
10.2.1 Overview, up to model year 2011.................................................................................................................................................................................................................................................................................................................................................................................................................... 7628
10.2.2 Exploded view of 4-spoke steering wheel, from model year 2012 onwards.............................................................................................................................................................................................................................................................................................................................................................................. 7630
10.2.3 Exploded view of 3-spoke steering wheel, from model year 2012 onwards.............................................................................................................................................................................................................................................................................................................................................................................. 7631
10.3 Removing and installing multifunction buttons in steering wheel -E441-/-E440-............................................................................................................................................................................................................................................................................................................................................................................ 7631
10.3.1 Removing and installing multifunction buttons, up to model year 2011............................................................................................................................................................................................................................................................................................................................................................................... 7631
10.3.2 Removing and installing multifunction buttons in 4-spoke steering wheel, from model year 2012 onwards.............................................................................................................................................................................................................................................................................................................................................. 7632
10.3.3 Removing and installing multifunction buttons in 3-spoke steering wheel, from model year 2012 onwards.............................................................................................................................................................................................................................................................................................................................................. 7635
10.4 Removing and installing tiptronic switches in steering wheel -E439-/-E438-............................................................................................................................................................................................................................................................................................................................................................................... 7637
10.4.1 Removing and installing tiptronic switches, up to model year 2011.................................................................................................................................................................................................................................................................................................................................................................................. 7637
10.4.2 Removing and installing tiptronic switches, from model year 2012 onwards........................................................................................................................................................................................................................................................................................................................................................................... 7638
11 Voice control system........................................................................................................................................................................................................................................................................................................................................................................................................................................... 7640
11.1 Layout - voice control system............................................................................................................................................................................................................................................................................................................................................................................................................................ 7640
11.2 Connector on speech input control unit................................................................................................................................................................................................................................................................................................................................................................................................................... 7642
11.3 Removing and installing voice control system............................................................................................................................................................................................................................................................................................................................................................................................................. 7642
11.3.1 Removing and installing speech input control unit -J507-, up to week 44/2008....................................................................................................................................................................................................................................................................................................................................................................... 7642
11.3.2 Removing and installing voice control system, from week 45/2008 onwards............................................................................................................................................................................................................................................................................................................................................................................ 7643
12 Connection for external multimedia devices..................................................................................................................................................................................................................................................................................................................................................................................................................... 7645
12.1 Layout - connection for external multimedia devices...................................................................................................................................................................................................................................................................................................................................................................................................... 7645
12.2 Connectors on connection for external audio sources...................................................................................................................................................................................................................................................................................................................................................................................................... 7646
12.2.2 Pin assignment for connection for external audio sources -R199- (interface)........................................................................................................................................................................................................................................................................................................................................................................ 7647
12.2.3 Pin assignment for AMI, CAN........................................................................................................................................................................................................................................................................................................................................................................................................................ 7647
12.2.4 Pin assignment for AUX IN.......................................................................................................................................................................................................................................................................................................................................................................................................................... 7648
12.3 Removing and installing connection for external audio sources -R199-..................................................................................................................................................................................................................................................................................................................................................................................... 7648
12.3.1 Removing and installing connection for external audio sources -R199-, AMI.......................................................................................................................................................................................................................................................................................................................................................................... 7648
12.3.2 Removing and installing connection for external audio sources -R199- (AUX IN)...................................................................................................................................................................................................................................................................................................................................................................... 7650
12.3.3 Removing and installing connection for external audio sources -R199- (interface)................................................................................................................................................................................................................................................................................................................................................................... 7650
13 Internet access................................................................................................................................................................................................................................................................................................................................................................................................................................................ 7652
13.1 Layout - internet access................................................................................................................................................................................................................................................................................................................................................................................................................................. 7652
13.2 Removing and installing internet access control unit -J666-.............................................................................................................................................................................................................................................................................................................................................................................................. 7652
13.3 Removing and installing internal battery for internet access control unit -J666-......................................................................................................................................................................................................................................................................................................................................................................... 7653
13.4 Pin assignment........................................................................................................................................................................................................................................................................................................................................................................................................................................... 7654
Direct_injection_and_ignition_system_(4-cyl__1_8_ltr___2_0_ltr__4-valve_turbo_-_generation_III)........................................................................................................................................................................................................................................................................................................................................................................... 7656
24 – Mixture preparation - injection.................................................................................................................................................................................................................................................................................................................................................................................................................................. 7660
1 Safety precautions and rules for cleanliness.................................................................................................................................................................................................................................................................................................................................................................................................................... 7660
1.1 General notes on self-diagnosis........................................................................................................................................................................................................................................................................................................................................................................................................................... 7660
1.2 Safety precautions when using testers and measuring instruments during a road test........................................................................................................................................................................................................................................................................................................................................................................ 7661
1.3 Safety precautions for vehicles with start/stop system.................................................................................................................................................................................................................................................................................................................................................................................................... 7661
1.4 Rules for cleanliness and instructions for working on fuel system......................................................................................................................................................................................................................................................................................................................................................................................... 7662
1.5 Safety precautions when working on the ignition system.................................................................................................................................................................................................................................................................................................................................................................................................... 7662
1.6 Reducing fuel pressure in high-pressure section........................................................................................................................................................................................................................................................................................................................................................................................................... 7663
1.7 Checking vacuum system.................................................................................................................................................................................................................................................................................................................................................................................................................................... 7664
2 Injection system................................................................................................................................................................................................................................................................................................................................................................................................................................................ 7665
2.1 Technical data............................................................................................................................................................................................................................................................................................................................................................................................................................................ 7665
2.2 Overview of fitting locations - injection system.......................................................................................................................................................................................................................................................................................................................................................................................................... 7665
3 Air cleaner..................................................................................................................................................................................................................................................................................................................................................................................................................................................... 7676
3.1 Exploded view - air cleaner............................................................................................................................................................................................................................................................................................................................................................................................................................... 7676
3.2 Removing and installing engine cover panel................................................................................................................................................................................................................................................................................................................................................................................................................ 7677
3.3 Removing and installing air filter element................................................................................................................................................................................................................................................................................................................................................................................................................ 7678
3.4 Removing air cleaner housing.............................................................................................................................................................................................................................................................................................................................................................................................................................. 7679
4 Intake manifold................................................................................................................................................................................................................................................................................................................................................................................................................................................. 7680
4.1 Exploded view - intake manifold........................................................................................................................................................................................................................................................................................................................................................................................................................... 7680
4.2 Exploded view - fuel rail (FSI)........................................................................................................................................................................................................................................................................................................................................................................................................................... 7682
4.3 Exploded view - fuel rail (MPI)........................................................................................................................................................................................................................................................................................................................................................................................................................... 7684
4.4 Removing and installing intake manifold................................................................................................................................................................................................................................................................................................................................................................................................................... 7685
4.5 Removing and installing fuel rail for FSI injectors....................................................................................................................................................................................................................................................................................................................................................................................................... 7689
4.6 Removing and installing throttle valve module -J338-...................................................................................................................................................................................................................................................................................................................................................................................................... 7689
4.7 Cleaning throttle valve module -J338-..................................................................................................................................................................................................................................................................................................................................................................................................................... 7690
4.8 Checking intake manifold change-over function............................................................................................................................................................................................................................................................................................................................................................................................................. 7690
5 High-pressure pump.............................................................................................................................................................................................................................................................................................................................................................................................................................................. 7693
5.1 Exploded view - high-pressure pump........................................................................................................................................................................................................................................................................................................................................................................................................................ 7693
5.2 Removing and installing high-pressure pump................................................................................................................................................................................................................................................................................................................................................................................................................ 7694
6 Injectors....................................................................................................................................................................................................................................................................................................................................................................................................................................................... 7698
6.1 Removing and installing FSI injectors..................................................................................................................................................................................................................................................................................................................................................................................................................... 7698
6.1.1 Renewing combustion chamber ring seal (teflon ring seal)............................................................................................................................................................................................................................................................................................................................................................................................ 7700
6.2 Removing and installing MPI injectors..................................................................................................................................................................................................................................................................................................................................................................................................................... 7702
6.3 Cleaning FSI injectors.................................................................................................................................................................................................................................................................................................................................................................................................................................... 7703
7 Senders and sensors............................................................................................................................................................................................................................................................................................................................................................................................................................................. 7705
7.1 Removing and installing fuel pressure sender -G247-....................................................................................................................................................................................................................................................................................................................................................................................................... 7705
7.2 Checking fuel pressure sender -G247-...................................................................................................................................................................................................................................................................................................................................................................................................................... 7706
7.3 Removing and installing fuel pressure sender for low pressure -G410-...................................................................................................................................................................................................................................................................................................................................................................................... 7708
7.4 Checking residual pressure in fuel system (up to high-pressure pump)...................................................................................................................................................................................................................................................................................................................................................................................... 7710
8 Lambda probes................................................................................................................................................................................................................................................................................................................................................................................................................................................... 7713
8.1 Overview - Lambda probes.................................................................................................................................................................................................................................................................................................................................................................................................................................. 7713
8.2 Removing and installing Lambda probe -G39- and Lambda probe heater -Z19- before catalytic converter....................................................................................................................................................................................................................................................................................................................................................... 7713
8.3 Removing and installing Lambda probe after catalytic converter -G130- and Lambda probe 1 heater after catalytic converter -Z29-........................................................................................................................................................................................................................................................................................................................... 7714
9 Engine control unit............................................................................................................................................................................................................................................................................................................................................................................................................................................. 7716
9.1 Wiring and component check with isolator boxes -VAS 6606-................................................................................................................................................................................................................................................................................................................................................................................................. 7716
9.2 Renewing engine control unit -J623-....................................................................................................................................................................................................................................................................................................................................................................................................................... 7717
28 – Ignition system.................................................................................................................................................................................................................................................................................................................................................................................................................................................. 7721
1 General notes and safety precautions............................................................................................................................................................................................................................................................................................................................................................................................................................ 7721
1.1 General notes on ignition system.......................................................................................................................................................................................................................................................................................................................................................................................................................... 7721
1.2 Safety precautions........................................................................................................................................................................................................................................................................................................................................................................................................................................ 7721
2 Servicing ignition system....................................................................................................................................................................................................................................................................................................................................................................................................................................... 7722
2.1 Test data................................................................................................................................................................................................................................................................................................................................................................................................................................................. 7722
2.2 Exploded view - ignition system........................................................................................................................................................................................................................................................................................................................................................................................................................... 7723
2.3 Removing and installing ignition coils with output stages................................................................................................................................................................................................................................................................................................................................................................................................. 7723
2.4 Removing knock sensor 1 -G61-............................................................................................................................................................................................................................................................................................................................................................................................................................. 7724
2.5 Removing and installing engine speed sender -G28-......................................................................................................................................................................................................................................................................................................................................................................................................... 7725
Direct_petrol_injection_and_ignition_system_(4-cyl__1_8_ltr__4-valve_turbo_with_timing_chain)............................................................................................................................................................................................................................................................................................................................................................................. 7726
24 – Mixture preparation - injection.................................................................................................................................................................................................................................................................................................................................................................................................................................. 7730
1 Safety precautions and rules for cleanliness.................................................................................................................................................................................................................................................................................................................................................................................................................... 7730
1.1 General notes on self-diagnosis........................................................................................................................................................................................................................................................................................................................................................................................................................... 7730
1.2 Safety precautions when using testers and measuring instruments during a road test........................................................................................................................................................................................................................................................................................................................................................................ 7730
1.3 Safety precautions for vehicles with start/stop system.................................................................................................................................................................................................................................................................................................................................................................................................... 7731
1.4 Safety precautions when working on the fuel system........................................................................................................................................................................................................................................................................................................................................................................................................ 7731
1.5 Rules for cleanliness and instructions for working on fuel system......................................................................................................................................................................................................................................................................................................................................................................................... 7732
1.6 Safety precautions when working on the ignition system.................................................................................................................................................................................................................................................................................................................................................................................................... 7733
1.7 Reducing pressure in high-pressure section of injection system............................................................................................................................................................................................................................................................................................................................................................................................ 7733
1.8 Checking vacuum system.................................................................................................................................................................................................................................................................................................................................................................................................................................... 7735
2 Injection system................................................................................................................................................................................................................................................................................................................................................................................................................................................ 7737
2.1 Technical data............................................................................................................................................................................................................................................................................................................................................................................................................................................ 7737
2.2 Overview of fitting locations............................................................................................................................................................................................................................................................................................................................................................................................................................. 7737
3 Air cleaner..................................................................................................................................................................................................................................................................................................................................................................................................................................................... 7747
3.1 Air cleaner - exploded view............................................................................................................................................................................................................................................................................................................................................................................................................................... 7747
3.2 Removing and installing engine cover panel................................................................................................................................................................................................................................................................................................................................................................................................................ 7748
3.3 Removing and installing air filter element................................................................................................................................................................................................................................................................................................................................................................................................................ 7748
3.4 Removing air cleaner housing.............................................................................................................................................................................................................................................................................................................................................................................................................................. 7750
4 Intake manifold................................................................................................................................................................................................................................................................................................................................................................................................................................................. 7753
4.1 Intake manifold - exploded view........................................................................................................................................................................................................................................................................................................................................................................................................................... 7753
4.2 Fuel rail - exploded view................................................................................................................................................................................................................................................................................................................................................................................................................................. 7754
4.3 Removing and installing intake manifold with fuel rail.................................................................................................................................................................................................................................................................................................................................................................................................... 7755
4.4 Removing and installing fuel rail......................................................................................................................................................................................................................................................................................................................................................................................................................... 7759
5 High-pressure pump.............................................................................................................................................................................................................................................................................................................................................................................................................................................. 7761
5.1 High-pressure pump - exploded view........................................................................................................................................................................................................................................................................................................................................................................................................................ 7761
5.2 Removing and installing high-pressure pump................................................................................................................................................................................................................................................................................................................................................................................................................ 7762
6 Injectors....................................................................................................................................................................................................................................................................................................................................................................................................................................................... 7765
6.1 Removing and installing injectors......................................................................................................................................................................................................................................................................................................................................................................................................................... 7765
6.1.1 Renewing combustion chamber ring seal (teflon ring seal)............................................................................................................................................................................................................................................................................................................................................................................................ 7766
6.2 Cleaning injectors........................................................................................................................................................................................................................................................................................................................................................................................................................................ 7768
7 Components of injection system.................................................................................................................................................................................................................................................................................................................................................................................................................................. 7770
7.1 Removing and installing fuel pressure sender -G247-....................................................................................................................................................................................................................................................................................................................................................................................................... 7770
7.2 Checking fuel pressure sender -G247-...................................................................................................................................................................................................................................................................................................................................................................................................................... 7771
7.3 Checking residual pressure in fuel system (up to high-pressure pump)...................................................................................................................................................................................................................................................................................................................................................................................... 7773
7.4 Removing and installing air mass meter -G70-.............................................................................................................................................................................................................................................................................................................................................................................................................. 7776
7.5 Removing and installing throttle valve module -J338-...................................................................................................................................................................................................................................................................................................................................................................................................... 7776
7.6 Cleaning throttle valve module -J338-..................................................................................................................................................................................................................................................................................................................................................................................................................... 7777
7.7 Checking intake manifold change-over function............................................................................................................................................................................................................................................................................................................................................................................................................. 7778
7.8 Checking dual non-return valve............................................................................................................................................................................................................................................................................................................................................................................................................................ 7779
8 Lambda probes................................................................................................................................................................................................................................................................................................................................................................................................................................................... 7782
8.1 Lambda probes - overview.................................................................................................................................................................................................................................................................................................................................................................................................................................. 7782
8.2 Removing and installing Lambda probe -G39- and Lambda probe heater -Z19- before catalytic converter....................................................................................................................................................................................................................................................................................................................................................... 7782
8.3 Removing and installing Lambda probe after catalytic converter -G130- and Lambda probe 1 heater after catalytic converter -Z29-........................................................................................................................................................................................................................................................................................................................... 7783
9 Engine control unit............................................................................................................................................................................................................................................................................................................................................................................................................................................. 7785
9.1 Wiring and component check with test box -V.A.G 1598/42-.................................................................................................................................................................................................................................................................................................................................................................................................. 7785
9.2 Renewing engine control unit -J623-....................................................................................................................................................................................................................................................................................................................................................................................................................... 7787
28 – Ignition system.................................................................................................................................................................................................................................................................................................................................................................................................................................................. 7791
1 General notes and safety precautions............................................................................................................................................................................................................................................................................................................................................................................................................................ 7791
1.1 General notes on ignition system.......................................................................................................................................................................................................................................................................................................................................................................................................................... 7791
1.2 Safety precautions........................................................................................................................................................................................................................................................................................................................................................................................................................................ 7791
2 Servicing ignition system....................................................................................................................................................................................................................................................................................................................................................................................................................................... 7792
2.1 Test data................................................................................................................................................................................................................................................................................................................................................................................................................................................. 7792
2.2 Ignition system - exploded view........................................................................................................................................................................................................................................................................................................................................................................................................................... 7792
2.3 Removing and installing ignition coils with output stages................................................................................................................................................................................................................................................................................................................................................................................................. 7793
2.4 Removing knock sensor 1 -G61-............................................................................................................................................................................................................................................................................................................................................................................................................................. 7794
2.5 Removing and installing engine speed sender -G28-......................................................................................................................................................................................................................................................................................................................................................................................................... 7794
Direct_petrol_injection_and_ignition_system_(4-cyl__2_0_ltr__4-valve_turbo_with_timing_chain)............................................................................................................................................................................................................................................................................................................................................................................. 7796
24 – Mixture preparation - injection.................................................................................................................................................................................................................................................................................................................................................................................................................................. 7800
1 Safety precautions and rules for cleanliness.................................................................................................................................................................................................................................................................................................................................................................................................................... 7800
1.1 General notes on self-diagnosis........................................................................................................................................................................................................................................................................................................................................................................................................................... 7800
1.2 Safety precautions when using testers and measuring instruments during a road test........................................................................................................................................................................................................................................................................................................................................................................ 7801
1.3 Safety precautions for vehicles with start/stop system.................................................................................................................................................................................................................................................................................................................................................................................................... 7801
1.4 Safety precautions and instructions for working on the fuel system........................................................................................................................................................................................................................................................................................................................................................................................ 7802
1.5 Safety precautions when working on the ignition system.................................................................................................................................................................................................................................................................................................................................................................................................... 7803
1.6 Reducing pressure in high-pressure section of injection system............................................................................................................................................................................................................................................................................................................................................................................................ 7803
1.7 Checking vacuum system.................................................................................................................................................................................................................................................................................................................................................................................................................................... 7805
2 Injection system................................................................................................................................................................................................................................................................................................................................................................................................................................................ 7807
2.1 Technical data............................................................................................................................................................................................................................................................................................................................................................................................................................................ 7807
2.2 Overview of fitting locations (vehicles with engine codes CDNB, CDNC, CAEB, CDZA, CAEA and CADA).......................................................................................................................................................................................................................................................................................................................................................... 7807
2.3 Overview of fitting locations (vehicles with engine codes CFKA, CPMA)..................................................................................................................................................................................................................................................................................................................................................................................... 7817
3 Air cleaner..................................................................................................................................................................................................................................................................................................................................................................................................................................................... 7827
3.1 Air cleaner - exploded view............................................................................................................................................................................................................................................................................................................................................................................................................................... 7827
3.2 Removing and installing engine cover panel................................................................................................................................................................................................................................................................................................................................................................................................................ 7828
3.3 Removing and installing air filter element................................................................................................................................................................................................................................................................................................................................................................................................................ 7828
3.4 Removing air cleaner housing.............................................................................................................................................................................................................................................................................................................................................................................................................................. 7830
4 Intake manifold (vehicles with engine codes CDNB, CDNC, CAEB, CDZA, CAEA and CADA).............................................................................................................................................................................................................................................................................................................................................................................. 7832
4.1 Intake manifold - exploded view........................................................................................................................................................................................................................................................................................................................................................................................................................... 7832
4.2 Fuel rail - exploded view................................................................................................................................................................................................................................................................................................................................................................................................................................. 7833
4.3 Removing and installing intake manifold................................................................................................................................................................................................................................................................................................................................................................................................................... 7834
4.4 Removing and installing fuel rail......................................................................................................................................................................................................................................................................................................................................................................................................................... 7838
5 Intake manifold (vehicles with engine codes CFKA, CPMA)......................................................................................................................................................................................................................................................................................................................................................................................................... 7840
5.1 Intake manifold - exploded view........................................................................................................................................................................................................................................................................................................................................................................................................................... 7840
5.2 Fuel rail - exploded view................................................................................................................................................................................................................................................................................................................................................................................................................................. 7842
5.3 Removing and installing intake manifold (top section)..................................................................................................................................................................................................................................................................................................................................................................................................... 7843
5.4 Removing and installing intake manifold (bottom section).................................................................................................................................................................................................................................................................................................................................................................................................. 7847
5.5 Removing and installing fuel rail......................................................................................................................................................................................................................................................................................................................................................................................................................... 7849
5.6 Removing and installing cold-start valve -N17-............................................................................................................................................................................................................................................................................................................................................................................................................ 7849
6 High-pressure pump.............................................................................................................................................................................................................................................................................................................................................................................................................................................. 7851
6.1 High-pressure pump - exploded view........................................................................................................................................................................................................................................................................................................................................................................................................................ 7851
6.2 Removing and installing high-pressure pump................................................................................................................................................................................................................................................................................................................................................................................................................ 7852
7 Injectors....................................................................................................................................................................................................................................................................................................................................................................................................................................................... 7855
7.1 Removing and installing injectors......................................................................................................................................................................................................................................................................................................................................................................................................................... 7855
7.1.1 Renewing combustion chamber ring seal (teflon ring seal)............................................................................................................................................................................................................................................................................................................................................................................................ 7856
7.2 Cleaning injectors........................................................................................................................................................................................................................................................................................................................................................................................................................................ 7858
8 Senders and sensors............................................................................................................................................................................................................................................................................................................................................................................................................................................. 7860
8.1 Removing and installing air mass meter -G70-.............................................................................................................................................................................................................................................................................................................................................................................................................. 7860
8.2 Removing and installing fuel pressure sender -G247-....................................................................................................................................................................................................................................................................................................................................................................................................... 7861
8.3 Checking fuel pressure sender -G247-...................................................................................................................................................................................................................................................................................................................................................................................................................... 7862
8.4 Checking residual pressure in fuel system (up to high-pressure pump)...................................................................................................................................................................................................................................................................................................................................................................................... 7864
8.5 Removing and installing throttle valve module -J338-...................................................................................................................................................................................................................................................................................................................................................................................................... 7867
8.6 Cleaning throttle valve module -J338-..................................................................................................................................................................................................................................................................................................................................................................................................................... 7867
8.7 Checking intake manifold change-over function............................................................................................................................................................................................................................................................................................................................................................................................................. 7868
8.8 Checking dual non-return valve............................................................................................................................................................................................................................................................................................................................................................................................................................ 7870
9 Lambda probes................................................................................................................................................................................................................................................................................................................................................................................................................................................... 7872
9.1 Lambda probes - overview.................................................................................................................................................................................................................................................................................................................................................................................................................................. 7872
9.2 Removing and installing Lambda probe -G39- and Lambda probe heater -Z19- before catalytic converter....................................................................................................................................................................................................................................................................................................................................................... 7873
9.3 Removing and installing Lambda probe after catalytic converter -G130- and Lambda probe 1 heater after catalytic converter -Z29-........................................................................................................................................................................................................................................................................................................................... 7874
10 Engine control unit............................................................................................................................................................................................................................................................................................................................................................................................................................................ 7876
10.1 Wiring and component check with test box -V.A.G 1598/42-................................................................................................................................................................................................................................................................................................................................................................................................. 7876
10.2 Renewing engine control unit -J623-...................................................................................................................................................................................................................................................................................................................................................................................................................... 7878
28 – Ignition system.................................................................................................................................................................................................................................................................................................................................................................................................................................................. 7882
1 General notes and safety precautions............................................................................................................................................................................................................................................................................................................................................................................................................................ 7882
1.1 General notes on ignition system.......................................................................................................................................................................................................................................................................................................................................................................................................................... 7882
1.2 Safety precautions........................................................................................................................................................................................................................................................................................................................................................................................................................................ 7882
2 Servicing ignition system....................................................................................................................................................................................................................................................................................................................................................................................................................................... 7883
2.1 Test data................................................................................................................................................................................................................................................................................................................................................................................................................................................. 7883
2.2 Ignition system - exploded view........................................................................................................................................................................................................................................................................................................................................................................................................................... 7884
2.3 Removing and installing ignition coils with output stages................................................................................................................................................................................................................................................................................................................................................................................................. 7884
2.4 Removing knock sensor 1 -G61-............................................................................................................................................................................................................................................................................................................................................................................................................................. 7886
2.5 Removing and installing engine speed sender -G28-......................................................................................................................................................................................................................................................................................................................................................................................................... 7886
Direct_petrol_injection_and_ignition_system_(8-cyl__4_2_ltr__4-valve)..................................................................................................................................................................................................................................................................................................................................................................................................... 7888
24 – Mixture preparation - injection.................................................................................................................................................................................................................................................................................................................................................................................................................................. 7892
1 Safety precautions and rules for cleanliness.................................................................................................................................................................................................................................................................................................................................................................................................................... 7892
1.1 General notes on self-diagnosis........................................................................................................................................................................................................................................................................................................................................................................................................................... 7892
1.2 Safety precautions........................................................................................................................................................................................................................................................................................................................................................................................................................................ 7892
1.3 Rules for cleanliness when working on the injection system................................................................................................................................................................................................................................................................................................................................................................................................ 7893
1.4 Important: Required procedure prior to opening high-pressure injection system............................................................................................................................................................................................................................................................................................................................................................................. 7894
1.5 Checking vacuum system.................................................................................................................................................................................................................................................................................................................................................................................................................................... 7895
2 Injection system................................................................................................................................................................................................................................................................................................................................................................................................................................................ 7897
2.1 Technical data............................................................................................................................................................................................................................................................................................................................................................................................................................................ 7897
2.2 Fitting locations - overview.............................................................................................................................................................................................................................................................................................................................................................................................................................. 7897
2.3 Air cleaner - exploded view............................................................................................................................................................................................................................................................................................................................................................................................................................... 7907
2.4 Removing and installing engine cover panel................................................................................................................................................................................................................................................................................................................................................................................................................ 7909
2.5 Removing and installing air filter element................................................................................................................................................................................................................................................................................................................................................................................................................ 7910
2.6 Removing air cleaner (bottom section)..................................................................................................................................................................................................................................................................................................................................................................................................................... 7911
2.7 Removing and installing air mass meter -G70-.............................................................................................................................................................................................................................................................................................................................................................................................................. 7915
2.8 Intake manifold (magnesium) - exploded view............................................................................................................................................................................................................................................................................................................................................................................................................... 7915
2.8.1 Removing and installing intake manifold............................................................................................................................................................................................................................................................................................................................................................................................................. 7917
2.8.2 Injectors with fuel rail - exploded view............................................................................................................................................................................................................................................................................................................................................................................................................ 7923
2.8.3 Removing and installing injectors................................................................................................................................................................................................................................................................................................................................................................................................................... 7925
2.9 Intake manifold (plastic - gradual introduction in model year 2009) - exploded view....................................................................................................................................................................................................................................................................................................................................................................... 7929
2.9.1 Removing and installing intake manifold............................................................................................................................................................................................................................................................................................................................................................................................................. 7932
2.9.2 Intake manifold (bottom section) with fuel rail - exploded view..................................................................................................................................................................................................................................................................................................................................................................................... 7937
2.9.3 Injectors and fuel rail - exploded view............................................................................................................................................................................................................................................................................................................................................................................................................. 7938
2.9.4 Removing and installing intake manifold (bottom section) with fuel rail............................................................................................................................................................................................................................................................................................................................................................................. 7939
2.9.5 Removing and installing injectors................................................................................................................................................................................................................................................................................................................................................................................................................... 7942
2.9.6 Connection diagram for vacuum hoses at intake manifold (plastic).................................................................................................................................................................................................................................................................................................................................................................................... 7945
2.10 Removing and installing fuel pressure sender -G247-...................................................................................................................................................................................................................................................................................................................................................................................................... 7946
2.11 Checking fuel pressure and residual pressure (up to high-pressure pump).................................................................................................................................................................................................................................................................................................................................................................................. 7947
2.12 High-pressure pump - exploded view....................................................................................................................................................................................................................................................................................................................................................................................................................... 7951
2.13 Removing and installing high-pressure pump............................................................................................................................................................................................................................................................................................................................................................................................................... 7954
2.14 Installing high-pressure pipes........................................................................................................................................................................................................................................................................................................................................................................................................................... 7956
2.15 Lambda probes - overview................................................................................................................................................................................................................................................................................................................................................................................................................................. 7958
2.16 Removing and installing Lambda probe before catalytic converter -G39- and Lambda probe after catalytic converter -G130- (cylinder bank 1)................................................................................................................................................................................................................................................................................................................ 7959
2.17 Removing and installing Lambda probe 2 before catalytic converter -G108- and Lambda probe after catalytic converter -G131- (cylinder bank 2)............................................................................................................................................................................................................................................................................................................. 7961
3 Engine control unit............................................................................................................................................................................................................................................................................................................................................................................................................................................. 7963
3.1 Wiring and component check with test box -V.A.G 1598/42-.................................................................................................................................................................................................................................................................................................................................................................................................. 7963
3.2 Removing and installing engine control unit -J623-........................................................................................................................................................................................................................................................................................................................................................................................................ 7964
28 – Ignition system.................................................................................................................................................................................................................................................................................................................................................................................................................................................. 7968
1 General notes and safety precautions............................................................................................................................................................................................................................................................................................................................................................................................................................ 7968
1.1 General notes on ignition system.......................................................................................................................................................................................................................................................................................................................................................................................................................... 7968
1.2 Safety precautions........................................................................................................................................................................................................................................................................................................................................................................................................................................ 7968
2 Servicing ignition system....................................................................................................................................................................................................................................................................................................................................................................................................................................... 7969
2.1 Test data................................................................................................................................................................................................................................................................................................................................................................................................................................................. 7969
2.2 Ignition system - exploded view........................................................................................................................................................................................................................................................................................................................................................................................................................... 7969
2.3 Removing and installing ignition coils.................................................................................................................................................................................................................................................................................................................................................................................................................... 7970
2.4 Removing and installing knock sensors..................................................................................................................................................................................................................................................................................................................................................................................................................... 7972
2.5 Removing and installing Hall sender....................................................................................................................................................................................................................................................................................................................................................................................................................... 7972
2.6 Removing and installing engine speed sender -G28-......................................................................................................................................................................................................................................................................................................................................................................................................... 7973
Direct_petrol_injection_and_ignition_system_(8-cyl__4_2_ltr__4-valve)__RS4__RS5........................................................................................................................................................................................................................................................................................................................................................................................... 7975
24 – Mixture preparation - injection.................................................................................................................................................................................................................................................................................................................................................................................................................................. 7979
1 Safety precautions and rules for cleanliness.................................................................................................................................................................................................................................................................................................................................................................................................................... 7979
1.1 General notes on self-diagnosis........................................................................................................................................................................................................................................................................................................................................................................................................................... 7979
1.2 Safety precautions when working on the fuel system........................................................................................................................................................................................................................................................................................................................................................................................................ 7980
1.3 Safety precautions when working on the injection and ignition system...................................................................................................................................................................................................................................................................................................................................................................................... 7980
1.4 Safety precautions when working on vehicles with start/stop system........................................................................................................................................................................................................................................................................................................................................................................................ 7981
1.5 Safety precautions when using testers and measuring instruments during a road test........................................................................................................................................................................................................................................................................................................................................................................ 7981
1.6 Rules for cleanliness and instructions for working on fuel system......................................................................................................................................................................................................................................................................................................................................................................................... 7981
1.7 Reducing pressure in high-pressure section of injection system............................................................................................................................................................................................................................................................................................................................................................................................ 7982
1.8 Checking for leaks in the fuel system..................................................................................................................................................................................................................................................................................................................................................................................................................... 7983
1.9 Checking vacuum system.................................................................................................................................................................................................................................................................................................................................................................................................................................... 7983
2 Injection system................................................................................................................................................................................................................................................................................................................................................................................................................................................ 7985
2.1 Technical data............................................................................................................................................................................................................................................................................................................................................................................................................................................ 7985
2.2 Overview of fitting locations - injection system.......................................................................................................................................................................................................................................................................................................................................................................................................... 7985
2.3 Exploded view - vacuum system............................................................................................................................................................................................................................................................................................................................................................................................................................. 7992
3 Air cleaner..................................................................................................................................................................................................................................................................................................................................................................................................................................................... 7994
3.1 Exploded view - air cleaner housing....................................................................................................................................................................................................................................................................................................................................................................................................................... 7994
3.2 Removing and installing engine cover panel................................................................................................................................................................................................................................................................................................................................................................................................................ 7995
3.3 Removing and installing air filter element................................................................................................................................................................................................................................................................................................................................................................................................................ 7996
3.4 Removing and installing air cleaner housing............................................................................................................................................................................................................................................................................................................................................................................................................... 7997
4 Intake manifold................................................................................................................................................................................................................................................................................................................................................................................................................................................. 7998
4.1 Exploded view - intake manifold (top section)............................................................................................................................................................................................................................................................................................................................................................................................................. 7998
4.2 Removing and installing throttle valve module -J338- / -J544-............................................................................................................................................................................................................................................................................................................................................................................................. 7999
4.3 Removing and installing intake manifold (top section)..................................................................................................................................................................................................................................................................................................................................................................................................... 8000
4.4 Exploded view - intake manifold (bottom section), fuel rail and injectors................................................................................................................................................................................................................................................................................................................................................................................. 8002
4.5 Removing and installing intake manifold (bottom section) with fuel rail................................................................................................................................................................................................................................................................................................................................................................................... 8005
5 High-pressure pump.............................................................................................................................................................................................................................................................................................................................................................................................................................................. 8009
5.1 Exploded view - high-pressure pump........................................................................................................................................................................................................................................................................................................................................................................................................................ 8009
5.2 Removing and installing high-pressure pump................................................................................................................................................................................................................................................................................................................................................................................................................ 8010
5.3 Removing and installing high-pressure pipe................................................................................................................................................................................................................................................................................................................................................................................................................ 8012
6 Injectors....................................................................................................................................................................................................................................................................................................................................................................................................................................................... 8016
6.1 Removing and installing injectors......................................................................................................................................................................................................................................................................................................................................................................................................................... 8016
6.1.1 Renewing combustion chamber ring seal (teflon ring seal)............................................................................................................................................................................................................................................................................................................................................................................................ 8018
6.2 Cleaning injectors........................................................................................................................................................................................................................................................................................................................................................................................................................................ 8020
7 Senders and sensors............................................................................................................................................................................................................................................................................................................................................................................................................................................. 8022
7.1 Removing and installing fuel pressure sender -G247- / -G624-.............................................................................................................................................................................................................................................................................................................................................................................................. 8022
7.2 Checking fuel pressure and residual pressure (up to high-pressure pump)................................................................................................................................................................................................................................................................................................................................................................................... 8022
8 Lambda probes................................................................................................................................................................................................................................................................................................................................................................................................................................................... 8027
8.1 Overview - Lambda probes.................................................................................................................................................................................................................................................................................................................................................................................................................................. 8027
8.2 Removing and installing Lambda probes..................................................................................................................................................................................................................................................................................................................................................................................................................... 8027
9 Engine control unit............................................................................................................................................................................................................................................................................................................................................................................................................................................. 8030
9.1 Wiring and component check with isolator boxes -VAS 6606-................................................................................................................................................................................................................................................................................................................................................................................................. 8030
9.2 Removing and installing engine control unit -J623-........................................................................................................................................................................................................................................................................................................................................................................................................ 8031
28 – Ignition system.................................................................................................................................................................................................................................................................................................................................................................................................................................................. 8035
1 General notes and safety precautions............................................................................................................................................................................................................................................................................................................................................................................................................................ 8035
1.1 General notes on ignition system.......................................................................................................................................................................................................................................................................................................................................................................................................................... 8035
1.2 Safety precautions........................................................................................................................................................................................................................................................................................................................................................................................................................................ 8035
2 Ignition system................................................................................................................................................................................................................................................................................................................................................................................................................................................. 8037
2.1 Test data................................................................................................................................................................................................................................................................................................................................................................................................................................................. 8037
2.2 Exploded view - ignition system........................................................................................................................................................................................................................................................................................................................................................................................................................... 8037
2.3 Removing and installing ignition coils.................................................................................................................................................................................................................................................................................................................................................................................................................... 8039
2.4 Removing and installing knock sensors -G61- / -G66- / -G198- / -G199-..................................................................................................................................................................................................................................................................................................................................................................................... 8040
2.5 Removing and installing Hall senders -G40- / -G163-....................................................................................................................................................................................................................................................................................................................................................................................................... 8041
2.6 Removing and installing Hall senders -G300- / -G301-...................................................................................................................................................................................................................................................................................................................................................................................................... 8042
2.7 Removing and installing engine speed sender -G28-......................................................................................................................................................................................................................................................................................................................................................................................................... 8043
Electrical_system......................................................................................................................................................................................................................................................................................................................................................................................................................................................... 8044
00 – Technical data................................................................................................................................................................................................................................................................................................................................................................................................................................................... 8052
1 Safety precautions.............................................................................................................................................................................................................................................................................................................................................................................................................................................. 8052
1.1 Safety precautions when working on vehicles with start/stop system........................................................................................................................................................................................................................................................................................................................................................................................ 8052
1.2 Safety precautions when using testers and measuring instruments during a road test........................................................................................................................................................................................................................................................................................................................................................................ 8052
1.3 Safety precautions when handling gas discharge bulbs...................................................................................................................................................................................................................................................................................................................................................................................................... 8053
2 Repair notes.................................................................................................................................................................................................................................................................................................................................................................................................................................................... 8055
2.1 Contact corrosion......................................................................................................................................................................................................................................................................................................................................................................................................................................... 8055
2.2 Routing and securing wiring............................................................................................................................................................................................................................................................................................................................................................................................................................... 8055
3 Battery......................................................................................................................................................................................................................................................................................................................................................................................................................................................... 8056
3.1 Battery - general notes................................................................................................................................................................................................................................................................................................................................................................................................................................... 8056
3.2 Battery types............................................................................................................................................................................................................................................................................................................................................................................................................................................. 8056
27 – Starter, current supply, CCS..................................................................................................................................................................................................................................................................................................................................................................................................................................... 8057
1 Battery......................................................................................................................................................................................................................................................................................................................................................................................................................................................... 8057
1.1 Exploded view - battery................................................................................................................................................................................................................................................................................................................................................................................................................................... 8057
1.1.1 Exploded view - battery, Coupé...................................................................................................................................................................................................................................................................................................................................................................................................................... 8057
1.1.2 Exploded view - battery, Sportback.................................................................................................................................................................................................................................................................................................................................................................................................................. 8059
1.2 Removing and installing battery........................................................................................................................................................................................................................................................................................................................................................................................................................... 8060
1.3 Disconnecting and connecting battery...................................................................................................................................................................................................................................................................................................................................................................................................................... 8065
1.4 Checking battery.......................................................................................................................................................................................................................................................................................................................................................................................................................................... 8067
1.5 Charging battery.......................................................................................................................................................................................................................................................................................................................................................................................................................................... 8067
1.6 Removing and installing earth cable with battery monitor control unit -J367-.............................................................................................................................................................................................................................................................................................................................................................................. 8070
1.7 Removing and installing battery cut-off relay/battery isolation igniter................................................................................................................................................................................................................................................................................................................................................................................... 8071
1.7.1 Removing and installing battery isolation igniter -N253-............................................................................................................................................................................................................................................................................................................................................................................................ 8071
2 Alternator...................................................................................................................................................................................................................................................................................................................................................................................................................................................... 8072
2.1 Exploded view - alternator................................................................................................................................................................................................................................................................................................................................................................................................................................ 8072
2.1.1 Exploded view - alternator without sliding bushes................................................................................................................................................................................................................................................................................................................................................................................................... 8072
2.1.2 Exploded view - alternator with sliding bushes...................................................................................................................................................................................................................................................................................................................................................................................................... 8073
2.1.3 Exploded view - alternator with sliding bushes, Audi RS 5........................................................................................................................................................................................................................................................................................................................................................................................... 8074
2.2 Removing and installing alternator........................................................................................................................................................................................................................................................................................................................................................................................................................ 8075
2.2.1 Removing and installing alternator - vehicles with 1.8 ltr. and 2.0 ltr. TFSI engine................................................................................................................................................................................................................................................................................................................................................................ 8075
2.2.2 Removing and installing alternator - vehicles with 3.0 ltr. TFSI and 3.2 ltr. FSI engine............................................................................................................................................................................................................................................................................................................................................................ 8076
2.2.3 Removing and installing alternator - vehicles with 4.2 ltr. FSI engine.............................................................................................................................................................................................................................................................................................................................................................................. 8078
2.2.4 Removing and installing alternator - vehicles with 2.0 ltr. TDI engine without SCR catalytic converter (PR number TH3 or TM4)....................................................................................................................................................................................................................................................................................................................... 8080
2.2.5 Removing and installing alternator - vehicles with 2.0 ltr. TDI engine with SCR catalytic converter (PR number TM4)................................................................................................................................................................................................................................................................................................................................. 8082
2.2.6 Removing and installing alternator - vehicles with 2.0 ltr. TDI engine with SCR catalytic converter (PR number TD1)................................................................................................................................................................................................................................................................................................................................. 8084
2.2.7 Removing and installing alternator - vehicles with 2.7 ltr. and 3.0 ltr. TDI engine without auxiliary heater........................................................................................................................................................................................................................................................................................................................................ 8086
2.2.8 Removing and installing alternator - vehicles with 2.7 ltr. and 3.0 ltr. TDI engine with auxiliary heater........................................................................................................................................................................................................................................................................................................................................... 8089
2.2.9 Removing and installing alternator - vehicles with 2.7 ltr. and 3.0 ltr. TDI engine with dual clutch gearbox........................................................................................................................................................................................................................................................................................................................................ 8095
2.2.10 Removing and installing alternator - Audi RS 5..................................................................................................................................................................................................................................................................................................................................................................................................... 8098
2.3 Checking alternator....................................................................................................................................................................................................................................................................................................................................................................................................................................... 8100
3 Starter......................................................................................................................................................................................................................................................................................................................................................................................................................................................... 8101
3.1 Exploded view - starter................................................................................................................................................................................................................................................................................................................................................................................................................................... 8101
3.1.1 Exploded view - starter............................................................................................................................................................................................................................................................................................................................................................................................................................. 8101
3.1.2 Exploded view - starter, Audi RS 5.................................................................................................................................................................................................................................................................................................................................................................................................................. 8102
3.2 Removing and installing starter........................................................................................................................................................................................................................................................................................................................................................................................................................... 8103
3.2.1 Removing and installing starter - vehicles with 1.8 ltr. and 2.0 ltr. TFSI engine................................................................................................................................................................................................................................................................................................................................................................... 8103
3.2.2 Removing and installing starter - vehicles with 3.0 ltr. TFSI and 3.2 ltr. FSI engine............................................................................................................................................................................................................................................................................................................................................................... 8105
3.2.3 Removing and installing starter - vehicles with 4.2 ltr. FSI engine................................................................................................................................................................................................................................................................................................................................................................................. 8106
3.2.4 Removing and installing starter - vehicles with 2.0 ltr. TDI engine (PR number TH3 or TM4).......................................................................................................................................................................................................................................................................................................................................................... 8109
3.2.5 Removing and installing starter - vehicles with 2.0 ltr. TDI engine (PR number TD1)................................................................................................................................................................................................................................................................................................................................................................. 8110
3.2.6 Removing and installing starter - vehicles with 2.7 ltr. and 3.0 ltr. TDI engine.................................................................................................................................................................................................................................................................................................................................................................... 8112
3.2.7 Removing and installing starter - vehicles with 2.7 ltr. and 3.0 ltr. TDI engine with dual clutch gearbox........................................................................................................................................................................................................................................................................................................................................... 8113
3.2.8 Removing and installing starter - Audi RS 5......................................................................................................................................................................................................................................................................................................................................................................................................... 8115
4 Start/stop system............................................................................................................................................................................................................................................................................................................................................................................................................................................... 8116
4.1 Exploded view - start/stop system......................................................................................................................................................................................................................................................................................................................................................................................................................... 8116
4.2 Removing and installing voltage stabiliser................................................................................................................................................................................................................................................................................................................................................................................................................ 8117
90 – Gauges, instruments.............................................................................................................................................................................................................................................................................................................................................................................................................................................. 8118
1 Dash panel insert............................................................................................................................................................................................................................................................................................................................................................................................................................................... 8118
1.1 Exploded view - dash panel insert......................................................................................................................................................................................................................................................................................................................................................................................................................... 8118
1.2 Removing and installing dash panel insert -KX2-........................................................................................................................................................................................................................................................................................................................................................................................................... 8120
1.3 Pin assignment on multi-pin connectors in dash panel insert............................................................................................................................................................................................................................................................................................................................................................................................... 8122
1.4 Pin assignment on fuel gauge senders...................................................................................................................................................................................................................................................................................................................................................................................................................... 8123
1.4.1 Pin assignment on fuel gauge sender -G-............................................................................................................................................................................................................................................................................................................................................................................................................. 8123
1.4.2 Pin assignment on fuel gauge sender 2 -G169-........................................................................................................................................................................................................................................................................................................................................................................................................ 8123
1.5 Pin assignment on coolant temperature sender.............................................................................................................................................................................................................................................................................................................................................................................................................. 8124
1.5.1 Pin assignment on coolant temperature sender -G62- - FSI engines.................................................................................................................................................................................................................................................................................................................................................................................... 8124
1.5.2 Pin assignment on coolant temperature senders -G62-/-G83- - vehicles with TDI engine................................................................................................................................................................................................................................................................................................................................................................ 8124
1.6 Removing and installing ambient temperature sensor........................................................................................................................................................................................................................................................................................................................................................................................................ 8125
1.6.1 Removing and installing ambient temperature sensor -G17- - vehicles up to model year 2011, USA vehicles up to model year 2012....................................................................................................................................................................................................................................................................................................................... 8125
1.6.2 Removing and installing ambient temperature sensor -G17- - vehicles from model year 2012 onwards, USA vehicles from model year 2013 onwards......................................................................................................................................................................................................................................................................................................... 8126
1.6.3 Removing and installing ambient temperature sensor -G17- - Audi RS 5................................................................................................................................................................................................................................................................................................................................................................................ 8126
2 Clock........................................................................................................................................................................................................................................................................................................................................................................................................................................................... 8127
2.1 Removing and installing radio-controlled clock receiver................................................................................................................................................................................................................................................................................................................................................................................................... 8127
3 Horn............................................................................................................................................................................................................................................................................................................................................................................................................................................................ 8128
3.1 Exploded view - horn...................................................................................................................................................................................................................................................................................................................................................................................................................................... 8128
3.2 Removing and installing treble horn -H2-/bass horn -H7-................................................................................................................................................................................................................................................................................................................................................................................................... 8129
3.2.1 Removing and installing horns -H2-/-H7- - Audi A5................................................................................................................................................................................................................................................................................................................................................................................................... 8129
3.2.2 Removing and installing horns -H2-/-H7- - Audi RS 5................................................................................................................................................................................................................................................................................................................................................................................................. 8130
92 – Windscreen wash/wipe system...................................................................................................................................................................................................................................................................................................................................................................................................................................... 8131
1 Windscreen wiper system......................................................................................................................................................................................................................................................................................................................................................................................................................................... 8131
1.1 Exploded view - windscreen wiper system................................................................................................................................................................................................................................................................................................................................................................................................................... 8131
1.1.1 Overview - windscreen wiper and washer system/headlight washer system............................................................................................................................................................................................................................................................................................................................................................................... 8131
1.1.2 Exploded view - windscreen wiper system............................................................................................................................................................................................................................................................................................................................................................................................................. 8133
1.1.3 Exploded view - windscreen wiper system, rain and light sensor...................................................................................................................................................................................................................................................................................................................................................................................... 8134
1.2 Moving windscreen wipers to service position.............................................................................................................................................................................................................................................................................................................................................................................................................. 8135
1.3 Removing and installing wiper blade....................................................................................................................................................................................................................................................................................................................................................................................................................... 8135
1.4 Removing and installing wiper arms........................................................................................................................................................................................................................................................................................................................................................................................................................ 8136
1.5 Adjusting wiper arms...................................................................................................................................................................................................................................................................................................................................................................................................................................... 8137
1.6 Removing and installing windscreen wiper motor -V-........................................................................................................................................................................................................................................................................................................................................................................................................ 8138
1.7 Renewing windscreen wiper motor........................................................................................................................................................................................................................................................................................................................................................................................................................... 8140
1.8 Removing and installing rain and light sensor............................................................................................................................................................................................................................................................................................................................................................................................................. 8140
1.8.1 Removing and installing rain and light sensor -G397- - vehicles up to model year 2011, USA vehicles up to model year 2012........................................................................................................................................................................................................................................................................................................................... 8140
1.8.2 Removing and installing rain and light sensor -G397- - vehicles from model year 2012 onwards, USA vehicles from model year 2013 onwards............................................................................................................................................................................................................................................................................................................. 8142
1.8.3 Renewing rain and light sensor -G397- - vehicles up to model year 2011, USA vehicles up to model year 2012.......................................................................................................................................................................................................................................................................................................................................... 8145
1.8.4 Renewing rain and light sensor -G397- - vehicles from model year 2012 onwards, USA vehicles from model year 2013 onwards............................................................................................................................................................................................................................................................................................................................ 8146
2 Windscreen washer system........................................................................................................................................................................................................................................................................................................................................................................................................................................ 8148
2.1 Exploded view - windscreen washer system.................................................................................................................................................................................................................................................................................................................................................................................................................. 8148
2.2 Removing and installing washer fluid reservoir............................................................................................................................................................................................................................................................................................................................................................................................................ 8150
2.2.1 Removing and installing filler neck for washer fluid reservoir...................................................................................................................................................................................................................................................................................................................................................................................... 8150
2.2.2 Removing and installing washer fluid reservoir...................................................................................................................................................................................................................................................................................................................................................................................................... 8151
2.3 Removing and installing windscreen washer fluid level sender.............................................................................................................................................................................................................................................................................................................................................................................................. 8152
2.4 Removing and installing washer pump....................................................................................................................................................................................................................................................................................................................................................................................................................... 8153
2.5 Removing and installing washer jets....................................................................................................................................................................................................................................................................................................................................................................................................................... 8154
2.6 Adjusting washer jets..................................................................................................................................................................................................................................................................................................................................................................................................................................... 8154
3 Headlight washer system......................................................................................................................................................................................................................................................................................................................................................................................................................................... 8156
3.1 Exploded view - headlight washer system................................................................................................................................................................................................................................................................................................................................................................................................................... 8156
3.2 Removing and installing washer fluid reservoir............................................................................................................................................................................................................................................................................................................................................................................................................ 8157
3.3 Removing and installing headlight washer system pump -V11-................................................................................................................................................................................................................................................................................................................................................................................................ 8157
3.4 Removing and installing washer jets....................................................................................................................................................................................................................................................................................................................................................................................................................... 8158
3.4.1 Removing and installing washer jets - Audi A5 (all vehicles), Audi RS 5 (vehicles up to model year 2011, USA vehicles up to model year 2012)........................................................................................................................................................................................................................................................................................................ 8158
3.4.2 Removing and installing washer jets - Audi RS 5 (vehicles from model year 2012 onwards, USA vehicles from model year 2013 onwards).................................................................................................................................................................................................................................................................................................................. 8160
3.5 Adjusting washer jets..................................................................................................................................................................................................................................................................................................................................................................................................................................... 8161
4 Washer fluid hoses.............................................................................................................................................................................................................................................................................................................................................................................................................................................. 8162
94 – Lights, bulbs, switches - exterior............................................................................................................................................................................................................................................................................................................................................................................................................................... 8163
1 Headlights...................................................................................................................................................................................................................................................................................................................................................................................................................................................... 8164
1.1 Exploded view - headlights................................................................................................................................................................................................................................................................................................................................................................................................................................ 8164
1.1.1 Exploded view - mounting for headlight housing, vehicles up to model year 2011, USA vehicles up to model year 2012.................................................................................................................................................................................................................................................................................................................................. 8165
1.1.2 Exploded view - mounting for headlight housing, vehicles from model year 2012 onwards, USA vehicles from model year 2013 onwards.................................................................................................................................................................................................................................................................................................................... 8167
1.1.3 Exploded view - halogen headlight, vehicles up to 10.2008........................................................................................................................................................................................................................................................................................................................................................................................... 8168
1.1.4 Exploded view - halogen headlight, vehicles from 11.2008 onwards.................................................................................................................................................................................................................................................................................................................................................................................... 8170
1.1.5 Exploded view - halogen headlight, vehicles from model year 2012 onwards, USA vehicles from model year 2013 onwards................................................................................................................................................................................................................................................................................................................................. 8172
1.1.6 Exploded view - gas discharge headlight with cornering light, vehicles up to model year 2011........................................................................................................................................................................................................................................................................................................................................................ 8175
1.1.7 Exploded view - gas discharge headlight with cornering light, USA vehicles up to model year 2012.................................................................................................................................................................................................................................................................................................................................................... 8178
1.1.8 Exploded view - gas discharge headlight, vehicles from model year 2012 onwards, USA vehicles from model year 2013 onwards........................................................................................................................................................................................................................................................................................................................... 8180
1.2 Removing and installing headlights........................................................................................................................................................................................................................................................................................................................................................................................................................ 8184
1.2.1 Removing and installing halogen headlights - vehicles up to 10.2008................................................................................................................................................................................................................................................................................................................................................................................. 8184
1.2.2 Removing and installing halogen headlights - vehicles from 11.2008 onwards.......................................................................................................................................................................................................................................................................................................................................................................... 8186
1.2.3 Removing and installing halogen headlights - vehicles from model year 2012 onwards, USA vehicles from model year 2013 onwards....................................................................................................................................................................................................................................................................................................................... 8187
1.2.4 Removing and installing gas discharge headlights with cornering light - vehicles up to model year 2011.............................................................................................................................................................................................................................................................................................................................................. 8188
1.2.5 Removing and installing gas discharge headlights with cornering light - USA vehicles up to model year 2012.......................................................................................................................................................................................................................................................................................................................................... 8190
1.2.6 Removing and installing gas discharge headlights - vehicles from model year 2012 onwards, USA vehicles from model year 2013 onwards................................................................................................................................................................................................................................................................................................................. 8192
1.3 Removing and installing mounting (top) for headlight housing - vehicles from model year 2012 onwards, USA vehicles from model year 2013 onwards........................................................................................................................................................................................................................................................................................................... 8194
1.4 Removing and installing bracket for mounting for headlight housing........................................................................................................................................................................................................................................................................................................................................................................................ 8194
1.5 Removing and installing mounting for headlight housing.................................................................................................................................................................................................................................................................................................................................................................................................... 8195
1.6 Removing and installing sealing frame..................................................................................................................................................................................................................................................................................................................................................................................................................... 8197
1.6.1 Removing and installing sealing frame, halogen headlights - vehicles from model year 2012 onwards, USA vehicles from model year 2013 onwards........................................................................................................................................................................................................................................................................................................ 8197
1.6.2 Removing and installing sealing frame, gas discharge headlights - vehicles from model year 2012 onwards, USA vehicles from model year 2013 onwards.................................................................................................................................................................................................................................................................................................. 8198
1.7 Removing and installing inner bracket for headlight housing............................................................................................................................................................................................................................................................................................................................................................................................... 8198
1.7.1 Removing and installing inner bracket for headlight housing, halogen headlights - vehicles from model year 2012 onwards, USA vehicles from model year 2013 onwards.................................................................................................................................................................................................................................................................................. 8198
1.7.2 Removing and installing inner bracket for headlight housing, gas discharge headlights - vehicles from model year 2012 onwards, USA vehicles from model year 2013 onwards............................................................................................................................................................................................................................................................................ 8199
1.8 Removing and installing bracket (top) for headlight housing............................................................................................................................................................................................................................................................................................................................................................................................... 8199
1.8.1 Removing and installing bracket (top) for headlight housing, halogen headlights - vehicles from model year 2012 onwards, USA vehicles from model year 2013 onwards.................................................................................................................................................................................................................................................................................. 8199
1.8.2 Removing and installing bracket (top) for headlight housing, gas discharge headlights - vehicles from model year 2012 onwards, USA vehicles from model year 2013 onwards............................................................................................................................................................................................................................................................................ 8199
1.9 Adjusting headlights...................................................................................................................................................................................................................................................................................................................................................................................................................................... 8200
1.9.1 Adjusting halogen headlights........................................................................................................................................................................................................................................................................................................................................................................................................................ 8200
1.9.2 Adjusting gas discharge headlights.................................................................................................................................................................................................................................................................................................................................................................................................................. 8203
1.9.3 Adjusting halogen headlights - USA vehicles up to model year 2012................................................................................................................................................................................................................................................................................................................................................................................... 8206
1.9.4 Adjusting halogen headlights - USA vehicles from model year 2013 onwards............................................................................................................................................................................................................................................................................................................................................................................ 8209
1.9.5 Adjusting gas discharge headlights - USA vehicles up to model year 2012............................................................................................................................................................................................................................................................................................................................................................................. 8211
1.9.6 Adjusting gas discharge headlights - USA vehicles from model year 2013 onwards...................................................................................................................................................................................................................................................................................................................................................................... 8214
1.10 Removing and installing front turn signal bulb -M5-/-M7-................................................................................................................................................................................................................................................................................................................................................................................................. 8218
1.10.1 Removing and installing front turn signal bulb -M5-/-M7-, halogen headlights - vehicles up to 10.2008.............................................................................................................................................................................................................................................................................................................................................. 8218
1.10.2 Removing and installing front turn signal bulb -M5-/-M7-, halogen headlights - vehicles from 11.2008 onwards....................................................................................................................................................................................................................................................................................................................................... 8219
1.10.3 Removing and installing front turn signal bulb -M5-/-M7-, halogen headlights - vehicles from model year 2012 onwards, USA vehicles from model year 2013 onwards.................................................................................................................................................................................................................................................................................... 8220
1.10.4 Removing and installing front turn signal bulb -M5-/-M7-, gas discharge headlights with cornering light - vehicles up to model year 2011........................................................................................................................................................................................................................................................................................................... 8221
1.10.5 Removing and installing front turn signal bulb -M5-/-M7-, gas discharge headlights with cornering light - USA vehicles up to model year 2012....................................................................................................................................................................................................................................................................................................... 8222
1.10.6 Removing and installing front turn signal bulb -M5-/-M7-, gas discharge headlights - vehicles from model year 2012 onwards, USA vehicles from model year 2013 onwards.............................................................................................................................................................................................................................................................................. 8224
1.11 Installing repair kit for headlight housing.............................................................................................................................................................................................................................................................................................................................................................................................................. 8225
1.11.1 Installing repair kit for headlight housing, halogen headlights - vehicles up to 10.2008........................................................................................................................................................................................................................................................................................................................................................... 8225
1.11.2 Installing repair kit for headlight housing, halogen headlights - vehicles from 11.2008 onwards.................................................................................................................................................................................................................................................................................................................................................... 8225
1.11.3 Installing repair kit for headlight housing, gas discharge headlights with cornering light - USA vehicles up to model year 2012.................................................................................................................................................................................................................................................................................................................... 8226
1.11.4 Installing repair kit for headlight housing, gas discharge headlights with cornering light - vehicles up to model year 2011........................................................................................................................................................................................................................................................................................................................ 8227
1.12 Adapting headlights for driving on the left side of the road............................................................................................................................................................................................................................................................................................................................................................................................. 8227
1.12.1 Adapting headlights for driving on the left side of the road, halogen headlights - vehicles up to model year 2011, USA vehicles up to model year 2012.............................................................................................................................................................................................................................................................................................. 8227
1.12.2 Adapting headlights for driving on the left side of the road, halogen headlights - vehicles from model year 2012 onwards, USA vehicles from model year 2013 onwards................................................................................................................................................................................................................................................................................ 8228
1.12.3 Adapting headlights for driving on the left or right side of the road, gas discharge headlights with cornering light - vehicles up to model year 2011, USA vehicles up to model year 2012.......................................................................................................................................................................................................................................................... 8229
1.12.4 Adapting headlights for driving on the left or right side of the road, gas discharge headlights - vehicles from model year 2012 onwards, USA vehicles from model year 2013 onwards................................................................................................................................................................................................................................................................. 8229
1.13 Adapting headlights for driving on the right side of the road............................................................................................................................................................................................................................................................................................................................................................................................ 8230
1.13.1 Adapting headlights for driving on the right side of the road, halogen headlights - vehicles up to 10.2008......................................................................................................................................................................................................................................................................................................................................... 8230
1.13.2 Adapting headlights for driving on the right side of the road, halogen headlights - vehicles from 11.2008 onwards.................................................................................................................................................................................................................................................................................................................................. 8231
1.13.3 Adapting headlights for driving on the right side of the road, halogen headlights - vehicles from model year 2012 onwards, USA vehicles from model year 2013 onwards............................................................................................................................................................................................................................................................................... 8232
1.13.4 Adapting headlights for driving on the left or right side of the road, gas discharge headlights with cornering light - vehicles up to model year 2011.............................................................................................................................................................................................................................................................................................. 8233
1.13.5 Adapting headlights for driving on the left or right side of the road, gas discharge headlights - vehicles from model year 2012 onwards, USA vehicles from model year 2013 onwards................................................................................................................................................................................................................................................................. 8233
1.14 Removing and installing headlight range control motor -V48-/-V49-........................................................................................................................................................................................................................................................................................................................................................................................ 8234
1.14.1 Removing and installing headlight range control motor -V48-/-V49-, halogen headlights - vehicles up to 10.2008..................................................................................................................................................................................................................................................................................................................................... 8234
1.14.2 Removing and installing headlight range control motor -V48-/-V49-, halogen headlights - vehicles from 11.2008 onwards.............................................................................................................................................................................................................................................................................................................................. 8236
1.14.3 Removing and installing headlight range control motor -V48-/-V49-, halogen headlights - vehicles from model year 2012 onwards, USA vehicles from model year 2013 onwards........................................................................................................................................................................................................................................................................... 8237
1.14.4 Removing and installing headlight range control motor -V48-/-V49-, gas discharge headlights with cornering light - vehicles up to model year 2011.................................................................................................................................................................................................................................................................................................. 8239
1.14.5 Removing and installing headlight range control motor -V48-/-V49-, gas discharge headlights with cornering light - USA vehicles up to model year 2012.............................................................................................................................................................................................................................................................................................. 8240
1.14.6 Removing and installing headlight range control motor -V48-/-V49-, gas discharge headlights - vehicles from model year 2012 onwards, USA vehicles from model year 2013 onwards..................................................................................................................................................................................................................................................................... 8242
1.15 Removing and installing headlight dipped beam bulb....................................................................................................................................................................................................................................................................................................................................................................................................... 8243
1.15.1 Removing and installing headlight dipped beam bulb -M29-/-M31-, halogen headlights - vehicles up to 10.2008........................................................................................................................................................................................................................................................................................................................................ 8243
1.15.2 Removing and installing headlight dipped beam bulb -M29-/-M31-, halogen headlights - vehicles from 11.2008 onwards................................................................................................................................................................................................................................................................................................................................. 8243
1.15.3 Removing and installing headlight dipped beam bulb -M29-/-M31-, halogen headlights - vehicles from model year 2012 onwards, USA vehicles from model year 2013 onwards.............................................................................................................................................................................................................................................................................. 8244
1.16 Removing and installing headlight main beam bulb -M30-/-M32-............................................................................................................................................................................................................................................................................................................................................................................................. 8245
1.16.1 Removing and installing headlight main beam bulb -M30-/-M32-, halogen headlights - vehicles up to 10.2008.......................................................................................................................................................................................................................................................................................................................................... 8245
1.16.2 Removing and installing headlight main beam bulb -M30-/-M32-, halogen headlights - vehicles from 11.2008 onwards................................................................................................................................................................................................................................................................................................................................... 8246
1.16.3 Removing and installing headlight main beam bulb -M30-/-M32-, halogen headlights - vehicles from model year 2012 onwards, USA vehicles from model year 2013 onwards................................................................................................................................................................................................................................................................................ 8247
1.17 Removing and installing gas discharge bulb -L13-/-L14-................................................................................................................................................................................................................................................................................................................................................................................................... 8248
1.17.1 Removing and installing gas discharge bulb -L13-/-L14-, gas discharge headlights with cornering light - vehicles up to model year 2011............................................................................................................................................................................................................................................................................................................. 8248
1.17.2 Removing and installing gas discharge bulb -L13-/-L14-, gas discharge headlights with cornering light - USA vehicles up to model year 2012......................................................................................................................................................................................................................................................................................................... 8249
1.17.3 Removing and installing gas discharge bulb -L13-/-L14-, gas discharge headlights - vehicles from model year 2012 onwards, USA vehicles from model year 2013 onwards................................................................................................................................................................................................................................................................................ 8250
1.18 Removing and installing side light bulb -M1-/-M3-........................................................................................................................................................................................................................................................................................................................................................................................................ 8251
1.18.1 Removing and installing side light bulb -M1-/-M3-, halogen headlights - vehicles up to 10.2008..................................................................................................................................................................................................................................................................................................................................................... 8251
1.18.2 Removing and installing side light bulb -M1-/-M3-, halogen headlights - vehicles from 11.2008 onwards.............................................................................................................................................................................................................................................................................................................................................. 8252
1.18.3 Removing and installing side light bulb -M1-/-M3-, halogen headlights - vehicles from model year 2012 onwards, USA vehicles from model year 2013 onwards........................................................................................................................................................................................................................................................................................... 8252
1.19 Removing and installing daytime running lights........................................................................................................................................................................................................................................................................................................................................................................................................... 8253
1.19.1 Removing and installing daytime running light bulb -L174-/-L175-, halogen headlights - vehicles up to 10.2008...................................................................................................................................................................................................................................................................................................................................... 8254
1.19.2 Removing and installing daytime running light bulb -L174-/-L175-, halogen headlights - vehicles from 11.2008 onwards............................................................................................................................................................................................................................................................................................................................... 8255
1.19.3 Removing and installing daytime running light bulb -L174-/-L175-, halogen headlights - vehicles from model year 2012 onwards, USA vehicles from model year 2013 onwards............................................................................................................................................................................................................................................................................ 8256
1.19.4 Removing and installing LED module for daytime running light and side light -L176-/-L177-, gas discharge headlights with cornering light - vehicles up to model year 2011.......................................................................................................................................................................................................................................................................... 8257
1.19.5 Removing and installing LED module for daytime running light and side light -L176-/-L177-, gas discharge headlights with cornering light - USA vehicles up to model year 2012...................................................................................................................................................................................................................................................................... 8257
1.19.6 Removing and installing LED module for daytime running light and side light -L176-/-L177-, gas discharge headlights - vehicles from model year 2012 onwards, USA vehicles from model year 2013 onwards............................................................................................................................................................................................................................................. 8257
1.19.7 Removing and installing control unit for daytime running light and side light -J860-/-J861-, gas discharge headlights - vehicles from model year 2012 onwards, USA vehicles from model year 2013 onwards........................................................................................................................................................................................................................................... 8258
1.20 Removing and installing dynamic cornering light control motor -V318-/-V319-.............................................................................................................................................................................................................................................................................................................................................................................. 8258
1.20.1 Removing and installing dynamic cornering light control motor -V318-/-V319-, gas discharge headlights with cornering light - vehicles up to model year 2011........................................................................................................................................................................................................................................................................................ 8258
1.20.2 Removing and installing dynamic cornering light control motor -V318-/-V319-, gas discharge headlights with cornering light - USA vehicles up to model year 2012.................................................................................................................................................................................................................................................................................... 8259
1.20.3 Removing and installing dynamic cornering light control motor -V318-/-V319-, gas discharge headlights - vehicles from model year 2012 onwards, USA vehicles from model year 2013 onwards........................................................................................................................................................................................................................................................... 8259
1.21 Removing and installing static cornering light -L148-/-L149-............................................................................................................................................................................................................................................................................................................................................................................................. 8259
1.21.1 Removing and installing static cornering light -M51-/-M52-, gas discharge headlights - vehicles from model year 2012 onwards, USA vehicles from model year 2013 onwards............................................................................................................................................................................................................................................................................ 8259
1.22 Removing and installing gas discharge bulb control unit -J343-/-J344-.................................................................................................................................................................................................................................................................................................................................................................................... 8260
1.22.1 Removing and installing gas discharge bulb control unit -J343-/-J344-, gas discharge headlights with cornering light - vehicles up to model year 2011.............................................................................................................................................................................................................................................................................................. 8260
1.22.2 Removing and installing gas discharge bulb control unit -J343-/-J344-, gas discharge headlights with cornering light - USA vehicles up to model year 2012.......................................................................................................................................................................................................................................................................................... 8261
1.22.3 Removing and installing gas discharge bulb control unit -J343-/-J344-, gas discharge headlights - vehicles from model year 2012 onwards, USA vehicles from model year 2013 onwards................................................................................................................................................................................................................................................................. 8262
1.23 Removing and installing output module for headlight -J667-/-J668-........................................................................................................................................................................................................................................................................................................................................................................................ 8263
1.23.1 Removing and installing output module for headlight -J667-/-J668-, gas discharge headlights with cornering light - vehicles up to model year 2011.................................................................................................................................................................................................................................................................................................. 8263
1.23.2 Removing and installing output module for headlight -J667-/-J668-, gas discharge headlights with cornering light - USA vehicles up to model year 2012.............................................................................................................................................................................................................................................................................................. 8263
1.23.3 Removing and installing output module for headlight -J667-/-J668-, gas discharge headlights - vehicles from model year 2012 onwards, USA vehicles from model year 2013 onwards..................................................................................................................................................................................................................................................................... 8265
1.24 Removing and installing dip beam screen motor -V294-/-V295-.............................................................................................................................................................................................................................................................................................................................................................................................. 8265
1.24.1 Removing and installing dip beam screen motor -V294-/-V295-, gas discharge headlights with cornering light - vehicles up to model year 2011........................................................................................................................................................................................................................................................................................................ 8265
1.24.2 Removing and installing dip beam screen motor -V294-/-V295-, gas discharge headlights with cornering light - USA vehicles up to model year 2012.................................................................................................................................................................................................................................................................................................... 8266
1.24.3 Removing and installing dip beam screen motor -V294-/-V295-, gas discharge headlights - vehicles from model year 2012 onwards, USA vehicles from model year 2013 onwards........................................................................................................................................................................................................................................................................... 8266
1.25 Removing and installing parking light bulb -M43-/-M44-................................................................................................................................................................................................................................................................................................................................................................................................... 8266
1.25.1 Removing and installing parking light bulb -M43-/-M44-, gas discharge headlights with cornering light - vehicles up to model year 2011............................................................................................................................................................................................................................................................................................................. 8266
1.25.2 Removing and installing parking light bulb -M43-/-M44-, gas discharge headlights with cornering light - USA vehicles up to model year 2012......................................................................................................................................................................................................................................................................................................... 8268
2 Fog lights...................................................................................................................................................................................................................................................................................................................................................................................................................................................... 8270
2.1 Exploded view - fog light................................................................................................................................................................................................................................................................................................................................................................................................................................. 8270
2.1.1 Exploded view - fog light, vehicles up to model year 2011, USA vehicles up to model year 2012....................................................................................................................................................................................................................................................................................................................................................... 8270
2.1.2 Exploded view - fog light, vehicles from model year 2012 onwards, USA vehicles from model year 2013 onwards......................................................................................................................................................................................................................................................................................................................................... 8271
2.2 Removing and installing fog lights........................................................................................................................................................................................................................................................................................................................................................................................................................ 8272
2.2.1 Removing and installing fog lights - vehicles up to model year 2011, USA vehicles up to model year 2012............................................................................................................................................................................................................................................................................................................................................. 8272
2.2.2 Removing and installing fog lights - vehicles from model year 2012 onwards, USA vehicles from model year 2013 onwards............................................................................................................................................................................................................................................................................................................................... 8273
2.3 Removing and installing fog light bulb -L22-/-L23-........................................................................................................................................................................................................................................................................................................................................................................................................ 8274
2.3.1 Removing and installing fog light bulb -L22-/-L23- - vehicles up to model year 2011, USA vehicles up to model year 2012............................................................................................................................................................................................................................................................................................................................. 8274
2.3.2 Removing and installing fog light bulb -L22-/-L23- - vehicles from model year 2012 onwards, USA vehicles from model year 2013 onwards............................................................................................................................................................................................................................................................................................................... 8274
2.4 Adjusting fog lights...................................................................................................................................................................................................................................................................................................................................................................................................................................... 8275
3 Side marker lights.............................................................................................................................................................................................................................................................................................................................................................................................................................................. 8276
3.1 Removing and installing front side marker bulb............................................................................................................................................................................................................................................................................................................................................................................................................ 8276
3.1.1 Removing and installing front side marker bulb -M33-/-M34-, halogen headlights - vehicles up to 10.2008............................................................................................................................................................................................................................................................................................................................................. 8276
3.1.2 Removing and installing front side marker bulb -M33-/-M34-, halogen headlights - vehicles from 11.2008 onwards...................................................................................................................................................................................................................................................................................................................................... 8277
3.1.3 Removing and installing front side marker light bulb -M33-/-M34-, halogen headlights - vehicles from model year 2012 onwards, USA vehicles from model year 2013 onwards............................................................................................................................................................................................................................................................................. 8277
3.1.4 Removing and installing front side marker light bulb -M33-/-M34-, gas discharge headlights with cornering light - USA vehicles up to model year 2012................................................................................................................................................................................................................................................................................................ 8278
3.1.5 Removing and installing front side marker light bulb -M33-/-M34-, gas discharge headlights - vehicles from model year 2012 onwards, USA vehicles from model year 2013 onwards....................................................................................................................................................................................................................................................................... 8278
3.2 Removing and installing output module for side marker light -J986-/-J987-, halogen headlights - vehicles from model year 2012 onwards, USA vehicles from model year 2013 onwards.......................................................................................................................................................................................................................................................................... 8278
3.3 Removing and installing rear side marker bulb -M37-/-M38-................................................................................................................................................................................................................................................................................................................................................................................................. 8279
4 Lights in exterior mirror....................................................................................................................................................................................................................................................................................................................................................................................................................................... 8280
4.1 Exploded view - lights in exterior mirror................................................................................................................................................................................................................................................................................................................................................................................................................. 8280
4.1.1 Exploded view - lights in exterior mirror, vehicles up to 05.2009................................................................................................................................................................................................................................................................................................................................................................................... 8280
4.1.2 Exploded view - lights in exterior mirror, vehicles from 06.2009 onwards............................................................................................................................................................................................................................................................................................................................................................................ 8281
4.2 Removing and installing exterior mirror turn signal bulb -L131-/-L132-.................................................................................................................................................................................................................................................................................................................................................................................... 8282
4.2.1 Removing and installing exterior mirror turn signal bulb -L131-/-L132- - vehicles up to 05.2009..................................................................................................................................................................................................................................................................................................................................................... 8282
4.2.2 Removing and installing exterior mirror turn signal bulb -L131-/-L132- - vehicles from 06.2009 onwards.............................................................................................................................................................................................................................................................................................................................................. 8283
5 Tail light cluster.............................................................................................................................................................................................................................................................................................................................................................................................................................................. 8284
5.1 Exploded view - tail light cluster on body................................................................................................................................................................................................................................................................................................................................................................................................................ 8284
5.1.1 Exploded view - tail light cluster on body.......................................................................................................................................................................................................................................................................................................................................................................................................... 8284
5.1.2 Exploded view - tail light cluster on body, USA vehicles............................................................................................................................................................................................................................................................................................................................................................................................ 8286
5.1.3 Exploded view - tail light cluster on body (LED), vehicles up to model year 2011.................................................................................................................................................................................................................................................................................................................................................................... 8287
5.1.4 Exploded view - tail light cluster on body (LED), USA vehicles up to model year 2012................................................................................................................................................................................................................................................................................................................................................................ 8288
5.1.5 Exploded view - tail light cluster on body (LED), vehicles from model year 2012 onwards, USA vehicles from model year 2013 onwards.................................................................................................................................................................................................................................................................................................................. 8289
5.2 Exploded view - tail light cluster on rear lid............................................................................................................................................................................................................................................................................................................................................................................................................ 8290
5.2.1 Exploded view - tail light cluster on rear lid...................................................................................................................................................................................................................................................................................................................................................................................................... 8290
5.2.2 Exploded view - tail light cluster on rear lid (LED), vehicles up to model year 2011, USA vehicles up to model year 2012............................................................................................................................................................................................................................................................................................................................ 8291
5.2.3 Exploded view - tail light cluster on rear lid (LED), vehicles from model year 2012 onwards, USA vehicles from model year 2013 onwards.............................................................................................................................................................................................................................................................................................................. 8292
5.3 Removing and installing bulb carrier...................................................................................................................................................................................................................................................................................................................................................................................................................... 8293
5.3.1 Removing and installing bulb holder................................................................................................................................................................................................................................................................................................................................................................................................................. 8293
5.3.2 Removing and installing bulb holder (LED) - vehicles up to model year 2011, USA vehicles up to model year 2012...................................................................................................................................................................................................................................................................................................................................... 8293
5.4 Removing and installing tail light cluster on rear lid.................................................................................................................................................................................................................................................................................................................................................................................................... 8294
5.4.1 Removing and installing inner tail light cluster.................................................................................................................................................................................................................................................................................................................................................................................................... 8294
5.4.2 Removing and installing inner tail light cluster (LED) - Audi A5 (vehicles up to model year 2011, USA vehicles up to model year 2012)............................................................................................................................................................................................................................................................................................................... 8295
5.4.3 Removing and installing inner tail light cluster (LED) - Audi RS 5 (vehicles up to model year 2011, USA vehicles up to model year 2012)............................................................................................................................................................................................................................................................................................................. 8296
5.4.4 Removing and installing inner tail light cluster (LED) - vehicles from model year 2012 onwards, USA vehicles from model year 2013 onwards........................................................................................................................................................................................................................................................................................................... 8298
5.5 Removing and installing tail light cluster................................................................................................................................................................................................................................................................................................................................................................................................................ 8300
5.5.1 Removing and installing outer tail light cluster.................................................................................................................................................................................................................................................................................................................................................................................................... 8300
5.5.2 Removing and installing outer tail light cluster (LED) - vehicles up to model year 2011, USA vehicles up to model year 2012......................................................................................................................................................................................................................................................................................................................... 8301
5.5.3 Removing and installing outer tail light cluster (LED) - vehicles from model year 2012 onwards, USA vehicles from model year 2013 onwards........................................................................................................................................................................................................................................................................................................... 8302
5.6 Removing and installing tail light bulb -M2-/-M4-......................................................................................................................................................................................................................................................................................................................................................................................................... 8302
5.6.1 Removing and installing tail light and rear fog light bulb -M41-/-M42-.............................................................................................................................................................................................................................................................................................................................................................................. 8302
5.7 Removing and installing rear fog light bulb -L46-/-L47-................................................................................................................................................................................................................................................................................................................................................................................................... 8304
5.7.1 Removing and installing rear fog light bulb -L46-/-L47- (LED) - Audi A5 (vehicles up to model year 2011, USA vehicles up to model year 2012)........................................................................................................................................................................................................................................................................................................ 8304
5.7.2 Removing and installing rear fog light bulb -L46-/-L47- (LED) - Audi RS 5 (vehicles up to model year 2011, USA vehicles up to model year 2012)...................................................................................................................................................................................................................................................................................................... 8304
5.8 Removing and installing reversing light bulb.............................................................................................................................................................................................................................................................................................................................................................................................................. 8305
5.8.1 Removing and installing reversing light bulb -M76-/-M77-............................................................................................................................................................................................................................................................................................................................................................................................ 8305
5.8.2 Removing and installing reversing light bulb -M16-/-M17- (LED) - Audi A5 (vehicles up to model year 2011, USA vehicles up to model year 2012)....................................................................................................................................................................................................................................................................................................... 8306
5.8.3 Removing and installing reversing light bulb -M16-/-M17- (LED) - Audi RS 5 (vehicles up to model year 2011, USA vehicles up to model year 2012)..................................................................................................................................................................................................................................................................................................... 8307
5.8.4 Removing and installing reversing light bulb -M16-/-M17- (LED) - vehicles from model year 2012 onwards, USA vehicles from model year 2013 onwards................................................................................................................................................................................................................................................................................................... 8309
6 High-level brake light.......................................................................................................................................................................................................................................................................................................................................................................................................................................... 8310
6.1 Exploded view - high-level brake light.................................................................................................................................................................................................................................................................................................................................................................................................................... 8310
6.1.1 Exploded view - high-level brake light and number plate light, Coupé................................................................................................................................................................................................................................................................................................................................................................................ 8310
6.1.2 Exploded view - high-level brake light and number plate light, Sportback............................................................................................................................................................................................................................................................................................................................................................................ 8311
6.2 Removing and installing high-level brake light bulb....................................................................................................................................................................................................................................................................................................................................................................................................... 8312
6.2.1 Removing and installing high-level brake light bulb -M25- - Coupé................................................................................................................................................................................................................................................................................................................................................................................... 8312
6.2.2 Removing and installing high-level brake light bulb -M25- - Sportback............................................................................................................................................................................................................................................................................................................................................................................... 8313
7 Number plate light.............................................................................................................................................................................................................................................................................................................................................................................................................................................. 8316
7.1 Removing and installing number plate light -X4-/-X5-...................................................................................................................................................................................................................................................................................................................................................................................................... 8316
7.1.1 Removing and installing number plate light -X4-/-X5- - Coupé........................................................................................................................................................................................................................................................................................................................................................................................ 8316
7.1.2 Removing and installing number plate light -X4-/-X5- - Sportback.................................................................................................................................................................................................................................................................................................................................................................................... 8316
8 Entry and start authorisation................................................................................................................................................................................................................................................................................................................................................................................................................................... 8317
8.1 Overview of fitting locations - entry and start authorisation system...................................................................................................................................................................................................................................................................................................................................................................................... 8317
8.2 Overview of fitting locations - keyless entry system...................................................................................................................................................................................................................................................................................................................................................................................................... 8319
8.3 Exploded view - exterior door handle for keyless entry system............................................................................................................................................................................................................................................................................................................................................................................................. 8322
8.4 Removing and installing central locking button in front exterior door handle.............................................................................................................................................................................................................................................................................................................................................................................. 8324
8.5 Removing and installing central locking button in rear exterior door handle............................................................................................................................................................................................................................................................................................................................................................................... 8325
8.6 Removing and installing interior aerial 1 for entry and start authorisation -R138-........................................................................................................................................................................................................................................................................................................................................................................ 8326
8.7 Removing and installing left aerial for entry and start authorisation..................................................................................................................................................................................................................................................................................................................................................................................... 8327
8.7.1 Removing and installing left aerial for entry and start authorisation -R200- - Coupé................................................................................................................................................................................................................................................................................................................................................................ 8327
8.7.2 Removing and installing left aerial for entry and start authorisation -R200- - Sportback............................................................................................................................................................................................................................................................................................................................................................ 8327
8.8 Removing and installing luggage compartment aerial for entry and start system -R137-...................................................................................................................................................................................................................................................................................................................................................................... 8328
8.8.1 Removing and installing luggage compartment aerial for entry and start authorisation -R137- - Coupé................................................................................................................................................................................................................................................................................................................................................. 8328
8.8.2 Removing and installing luggage compartment aerial for entry and start authorisation -R137- - Sportback............................................................................................................................................................................................................................................................................................................................................. 8329
9 Steering column switch module................................................................................................................................................................................................................................................................................................................................................................................................................................... 8330
9.1 Exploded view - steering column switch module............................................................................................................................................................................................................................................................................................................................................................................................................. 8330
9.2 Removing and installing steering column switch module..................................................................................................................................................................................................................................................................................................................................................................................................... 8332
9.3 Removing and installing steering column electronics control unit -J527-................................................................................................................................................................................................................................................................................................................................................................................... 8333
9.4 Removing and installing turn signal switch -E2-........................................................................................................................................................................................................................................................................................................................................................................................................... 8334
9.5 Removing and installing cruise control system switch -E45-................................................................................................................................................................................................................................................................................................................................................................................................ 8335
9.6 Removing and installing intermittent wiper switch -E22-................................................................................................................................................................................................................................................................................................................................................................................................... 8335
9.7 Pin assignment on steering column electronics control unit................................................................................................................................................................................................................................................................................................................................................................................................ 8335
9.8 Removing and installing entry and start authorisation switch -E415-....................................................................................................................................................................................................................................................................................................................................................................................... 8337
10 Parking aid.................................................................................................................................................................................................................................................................................................................................................................................................................................................... 8340
10.1 Overview - parking aid................................................................................................................................................................................................................................................................................................................................................................................................................................... 8340
10.2 Removing and installing parking aid control unit -J446-.................................................................................................................................................................................................................................................................................................................................................................................................. 8342
10.2.1 Removing and installing parking aid control unit -J446- - vehicles without towing bracket.......................................................................................................................................................................................................................................................................................................................................................... 8342
10.2.2 Removing and installing parking aid control unit -J446- - vehicles with towing bracket............................................................................................................................................................................................................................................................................................................................................................. 8343
10.3 Removing and installing front parking aid warning buzzer -H22-........................................................................................................................................................................................................................................................................................................................................................................................... 8344
10.4 Removing and installing rear parking aid warning buzzer -H15-............................................................................................................................................................................................................................................................................................................................................................................................ 8344
10.4.1 Removing and installing rear parking aid warning buzzer -H15- - Coupé.............................................................................................................................................................................................................................................................................................................................................................................. 8344
10.4.2 Removing and installing rear parking aid warning buzzer -H15- - Sportback.......................................................................................................................................................................................................................................................................................................................................................................... 8345
10.5 Removing and installing front parking aid senders........................................................................................................................................................................................................................................................................................................................................................................................................ 8345
10.5.1 Removing and installing front parking aid sender -G252-/-G253-/-G254-/-G255- - Audi A5 (vehicles up to model year 2011, USA vehicles up to model year 2012)........................................................................................................................................................................................................................................................................................ 8345
10.5.2 Removing and installing front parking aid sender -G252-/-G253-/-G254-/-G255- - Audi A5 (vehicles from model year 2012 onwards, USA vehicles from model year 2013 onwards).......................................................................................................................................................................................................................................................................... 8346
10.5.3 Removing and installing front parking aid sender -G252-/-G253-/-G254-/-G255- - Audi RS 5 (vehicles up to model year 2011, USA vehicles up to model year 2012)...................................................................................................................................................................................................................................................................................... 8346
10.5.4 Removing and installing front parking aid sender -G252-/-G253-/-G254-/-G255- - Audi RS 5 (vehicles from model year 2012 onwards, USA vehicles from model year 2013 onwards)........................................................................................................................................................................................................................................................................ 8347
10.6 Removing and installing rear parking aid senders......................................................................................................................................................................................................................................................................................................................................................................................................... 8348
10.6.1 Removing and installing rear parking aid sender -G203-/-G204-/-G205-/-G206- - Coupé................................................................................................................................................................................................................................................................................................................................................................ 8348
10.6.2 Removing and installing rear parking aid sender -G203-/-G204-/-G205-/-G206- - Sportback............................................................................................................................................................................................................................................................................................................................................................ 8349
11 Automatic headlight range control.............................................................................................................................................................................................................................................................................................................................................................................................................................. 8350
11.1 Overview - automatic headlight range control............................................................................................................................................................................................................................................................................................................................................................................................................. 8350
11.2 Removing and installing headlight range control unit..................................................................................................................................................................................................................................................................................................................................................................................................... 8351
96 – Lights, bulbs, switches - interior............................................................................................................................................................................................................................................................................................................................................................................................................................... 8352
1 Lights.......................................................................................................................................................................................................................................................................................................................................................................................................................................................... 8353
1.1 Overview of fitting locations - lights in dash panel...................................................................................................................................................................................................................................................................................................................................................................................................... 8353
1.2 Overview of fitting locations - lights in front doors..................................................................................................................................................................................................................................................................................................................................................................................................... 8355
1.2.1 Overview of fitting locations - lights in front doors, Coupé........................................................................................................................................................................................................................................................................................................................................................................................ 8355
1.2.2 Overview of fitting locations - lights in front doors, Sportback.................................................................................................................................................................................................................................................................................................................................................................................... 8356
1.3 Overview of fitting locations - lights in rear doors...................................................................................................................................................................................................................................................................................................................................................................................................... 8357
1.4 Overview of fitting locations - lights in centre console.................................................................................................................................................................................................................................................................................................................................................................................................. 8358
1.5 Overview of fitting locations - lights in luggage compartment............................................................................................................................................................................................................................................................................................................................................................................................. 8359
1.6 Overview of fitting locations - lights in roof trim....................................................................................................................................................................................................................................................................................................................................................................................................... 8360
1.7 Removing and installing glove compartment light -W6-...................................................................................................................................................................................................................................................................................................................................................................................................... 8360
1.8 Removing and installing front left footwell illumination bulb -L151-/front right footwell illumination bulb -L152-........................................................................................................................................................................................................................................................................................................................................ 8361
1.9 Removing and installing central locking SAFELOCK function warning lamp -K133-............................................................................................................................................................................................................................................................................................................................................................................. 8362
1.9.1 Removing and installing central locking SAFELOCK function warning lamp -K133- - Coupé............................................................................................................................................................................................................................................................................................................................................................... 8362
1.9.2 Removing and installing central locking SAFELOCK function warning lamp -K133- - Sportback........................................................................................................................................................................................................................................................................................................................................................... 8363
1.10 Removing and installing door opener illumination bulb -L108-/-L109-...................................................................................................................................................................................................................................................................................................................................................................................... 8363
1.10.1 Removing and installing door opener illumination bulb -L108-/-L109- - Coupé........................................................................................................................................................................................................................................................................................................................................................................ 8363
1.10.2 Removing and installing door opener illumination bulb -L108-/-L109- - Sportback.................................................................................................................................................................................................................................................................................................................................................................... 8364
1.11 Removing and installing front entry light -W31-/-W32-.................................................................................................................................................................................................................................................................................................................................................................................................... 8364
1.11.1 Removing and installing front entry light -W31-/-W32- - Coupé...................................................................................................................................................................................................................................................................................................................................................................................... 8364
1.11.2 Removing and installing front entry light -W31-/-W32- - Sportback.................................................................................................................................................................................................................................................................................................................................................................................. 8365
1.12 Removing and installing door warning lamp -W30-/-W36-.................................................................................................................................................................................................................................................................................................................................................................................................... 8367
1.12.1 Removing and installing door warning lamp -W30-/-W36- - Coupé...................................................................................................................................................................................................................................................................................................................................................................................... 8367
1.12.2 Removing and installing door warning lamp -W30-/-W36- - Sportback.................................................................................................................................................................................................................................................................................................................................................................................. 8368
1.13 Removing and installing door opener illumination bulb -L110-/-L111-...................................................................................................................................................................................................................................................................................................................................................................................... 8369
1.14 Removing and installing rear entry light -W33-/-W34-..................................................................................................................................................................................................................................................................................................................................................................................................... 8369
1.15 Removing and installing rear door warning lamp -W37-/-W38-............................................................................................................................................................................................................................................................................................................................................................................................... 8371
1.16 Removing and installing selector lever position display -Y26-............................................................................................................................................................................................................................................................................................................................................................................................ 8372
1.17 Removing and installing footwell light (rear) -W45-/-W46-................................................................................................................................................................................................................................................................................................................................................................................................ 8373
1.18 Removing and installing luggage compartment light -W3-................................................................................................................................................................................................................................................................................................................................................................................................... 8373
1.18.1 Removing and installing luggage compartment light -W3- - Coupé..................................................................................................................................................................................................................................................................................................................................................................................... 8373
1.18.2 Removing and installing luggage compartment light -W18-/-W3-/-W61- - Sportback..................................................................................................................................................................................................................................................................................................................................................................... 8374
1.19 Renewing bulb for front interior light -W1-/-W13-/-W19-.................................................................................................................................................................................................................................................................................................................................................................................................. 8375
1.19.1 Renewing bulbs for front interior light -W1-....................................................................................................................................................................................................................................................................................................................................................................................................... 8375
1.19.2 Renewing reading light bulbs (front) -W13-/-W19-................................................................................................................................................................................................................................................................................................................................................................................................... 8376
1.20 Renewing bulb for rear interior light -W47-/-W48-........................................................................................................................................................................................................................................................................................................................................................................................................ 8376
1.20.1 Renewing bulbs for rear interior light -W47-/-W48-................................................................................................................................................................................................................................................................................................................................................................................................. 8376
1.20.2 Renewing bulb for rear interior light -W47-/-W48-.................................................................................................................................................................................................................................................................................................................................................................................................. 8377
1.21 Removing and installing LED for background lighting...................................................................................................................................................................................................................................................................................................................................................................................................... 8378
1.22 Removing and installing dash panel vent illumination bulb (left and right) -L67-/-L69-................................................................................................................................................................................................................................................................................................................................................................... 8378
1.23 Removing and installing vanity mirror light bulb -L31-................................................................................................................................................................................................................................................................................................................................................................................................... 8379
2 Controls........................................................................................................................................................................................................................................................................................................................................................................................................................................................ 8381
2.1 Overview of fitting locations - controls in dash panel.................................................................................................................................................................................................................................................................................................................................................................................................... 8382
2.2 Overview of fitting locations - controls in front doors................................................................................................................................................................................................................................................................................................................................................................................................... 8384
2.2.1 Overview of fitting locations - controls in front doors, Coupé...................................................................................................................................................................................................................................................................................................................................................................................... 8384
2.2.2 Overview of fitting locations - controls in front doors, Sportback.................................................................................................................................................................................................................................................................................................................................................................................. 8385
2.3 Overview of fitting locations - controls in rear doors.................................................................................................................................................................................................................................................................................................................................................................................................... 8386
2.4 Overview of fitting locations - controls in centre console................................................................................................................................................................................................................................................................................................................................................................................................ 8387
2.5 Overview of fitting locations - controls in luggage compartment........................................................................................................................................................................................................................................................................................................................................................................................... 8388
2.6 Overview of fitting locations - controls in roof trim..................................................................................................................................................................................................................................................................................................................................................................................................... 8389
2.7 Removing and installing rotary light switch -EX1-......................................................................................................................................................................................................................................................................................................................................................................................................... 8390
2.8 Removing and installing switch and instrument illumination regulator -E20-................................................................................................................................................................................................................................................................................................................................................................................ 8391
2.9 Removing and installing headlight range control regulator -E102-.......................................................................................................................................................................................................................................................................................................................................................................................... 8392
2.10 Removing and installing start/stop operation button -E693-............................................................................................................................................................................................................................................................................................................................................................................................... 8393
2.10.1 Removing and installing start/stop operation button -E693- - vehicles up to model year 2011, USA vehicles up to model year 2012.................................................................................................................................................................................................................................................................................................................... 8393
2.11 Removing and installing front passenger side airbag deactivated warning lamp -K145-...................................................................................................................................................................................................................................................................................................................................................................... 8393
2.12 Removing and installing switches in dash panel........................................................................................................................................................................................................................................................................................................................................................................................................... 8394
2.12.1 Removing and installing switch panel in dash panel - vehicles equipped with MMI convenience........................................................................................................................................................................................................................................................................................................................................................ 8394
2.13 Removing and installing front heated seat regulator -E94-/-E95-.......................................................................................................................................................................................................................................................................................................................................................................................... 8394
2.14 Removing and installing hazard warning lights button -E229-.............................................................................................................................................................................................................................................................................................................................................................................................. 8394
2.15 Removing and installing valet parking button -E536-...................................................................................................................................................................................................................................................................................................................................................................................................... 8395
2.16 Removing and installing glove compartment light switch -E26-............................................................................................................................................................................................................................................................................................................................................................................................. 8396
2.17 Removing and installing mirror adjustment switch -E43-/-E168-............................................................................................................................................................................................................................................................................................................................................................................................ 8397
2.17.1 Removing and installing mirror adjustment switch -E43-/-E168- - Coupé.............................................................................................................................................................................................................................................................................................................................................................................. 8397
2.17.2 Removing and installing mirror adjustment switch -E43-/-E168- - Sportback.......................................................................................................................................................................................................................................................................................................................................................................... 8397
2.18 Removing and installing operating unit for window regulator in driver door -E512-........................................................................................................................................................................................................................................................................................................................................................................ 8398
2.18.1 Removing and installing window regulator switch -E512-/-E107- - Coupé.............................................................................................................................................................................................................................................................................................................................................................................. 8398
2.18.2 Removing and installing window regulator switch -E512-/-E107- - Sportback.......................................................................................................................................................................................................................................................................................................................................................................... 8399
2.19 Removing and installing driver seat/front passenger seat memory operating unit -E97-/-E277-.............................................................................................................................................................................................................................................................................................................................................................. 8400
2.19.1 Removing and installing driver seat memory operating unit -E97- - Coupé............................................................................................................................................................................................................................................................................................................................................................................ 8400
2.19.2 Removing and installing driver seat memory operating unit -E97- - Sportback........................................................................................................................................................................................................................................................................................................................................................................ 8401
2.20 Removing and installing door contact switch -F2-/-F3-.................................................................................................................................................................................................................................................................................................................................................................................................... 8401
2.21 Removing and installing rear interior locking switch -E273-/-E274-....................................................................................................................................................................................................................................................................................................................................................................................... 8401
2.22 Removing and installing door contact switch (rear) -F10-/-F11-........................................................................................................................................................................................................................................................................................................................................................................................... 8402
2.23 Removing and installing electromechanical parking brake button -E538-/auto-hold button -E540-............................................................................................................................................................................................................................................................................................................................................................ 8402
2.24 Removing and installing entry and start authorisation button -E408-...................................................................................................................................................................................................................................................................................................................................................................................... 8402
2.24.1 Removing and installing entry and start authorisation button -E408- - vehicles with manual gearbox................................................................................................................................................................................................................................................................................................................................................. 8402
2.24.2 Removing and installing entry and start authorisation button -E408- - vehicles with automatic gearbox.............................................................................................................................................................................................................................................................................................................................................. 8404
2.25 Removing and installing heated rear seat switch with regulator -E128-/-E129-............................................................................................................................................................................................................................................................................................................................................................................. 8404
2.26 Removing and installing rear lid contact switch.......................................................................................................................................................................................................................................................................................................................................................................................................... 8405
2.27 Removing and installing contact switch for vanity mirror -F147-/-F148-................................................................................................................................................................................................................................................................................................................................................................................... 8405
2.28 Removing and installing sunroof button -E325-............................................................................................................................................................................................................................................................................................................................................................................................................ 8405
2.28.1 Removing and installing button 1 for tilting roof -E582- - Coupé................................................................................................................................................................................................................................................................................................................................................................................... 8405
2.28.2 Removing and installing sliding sunroof adjustment regulator -E139- - Sportback.................................................................................................................................................................................................................................................................................................................................................................... 8406
2.29 Removing and installing interior light/reading light (front)............................................................................................................................................................................................................................................................................................................................................................................................. 8406
2.30 Removing and installing interior light/reading light (rear).............................................................................................................................................................................................................................................................................................................................................................................................. 8406
2.30.1 Removing and installing interior light/reading light (rear)........................................................................................................................................................................................................................................................................................................................................................................................ 8406
2.30.2 Removing and installing rear interior light........................................................................................................................................................................................................................................................................................................................................................................................................ 8407
2.31 Removing and installing garage door operating unit -E284-................................................................................................................................................................................................................................................................................................................................................................................................ 8408
2.32 Removing and installing switch panel in centre console................................................................................................................................................................................................................................................................................................................................................................................................... 8408
2.32.1 Removing and installing switch panel in centre console - vehicles equipped with MMI basic.......................................................................................................................................................................................................................................................................................................................................................... 8408
2.33 Removing and installing rear lid remote release switch -E188-............................................................................................................................................................................................................................................................................................................................................................................................ 8408
2.34 Removing and installing window regulator switches -E52-/-E54-............................................................................................................................................................................................................................................................................................................................................................................................ 8409
2.35 Removing and installing buttons for rear seat heating -E737-/-E738-...................................................................................................................................................................................................................................................................................................................................................................................... 8410
2.36 Removing and installing adjustable rear spoiler switch -E127-............................................................................................................................................................................................................................................................................................................................................................................................ 8410
2.37 Removing and installing interior locking switch -E150-/-E198-............................................................................................................................................................................................................................................................................................................................................................................................ 8411
2.37.1 Removing and installing driver side interior locking switch -E150-/front passenger side interior locking switch -E198- - Coupé..................................................................................................................................................................................................................................................................................................................... 8411
2.37.2 Removing and installing driver side interior locking switch -E150-/front passenger side interior locking switch -E198- - Sportback................................................................................................................................................................................................................................................................................................................. 8411
2.38 Removing and installing interior monitoring switch -E183-/alarm system off switch -E217-................................................................................................................................................................................................................................................................................................................................................................. 8412
2.38.1 Removing and installing interior monitoring switch -E183-/alarm system off switch -E217- - Coupé................................................................................................................................................................................................................................................................................................................................................... 8412
2.38.2 Removing and installing interior monitoring switch -E183-/alarm system off switch -E217- - Sportback............................................................................................................................................................................................................................................................................................................................................... 8412
3 Anti-theft alarm system......................................................................................................................................................................................................................................................................................................................................................................................................................................... 8414
3.1 Overview - interior monitoring............................................................................................................................................................................................................................................................................................................................................................................................................................ 8414
3.2 Removing and installing alarm horn -H12-.................................................................................................................................................................................................................................................................................................................................................................................................................. 8415
3.3 Removing and installing anti-theft alarm sensor -G578-.................................................................................................................................................................................................................................................................................................................................................................................................... 8416
4 Lane change assist.............................................................................................................................................................................................................................................................................................................................................................................................................................................. 8417
4.1 Overview - lane change assist............................................................................................................................................................................................................................................................................................................................................................................................................................. 8417
4.2 Removing and installing button for lane change assist -E530-.............................................................................................................................................................................................................................................................................................................................................................................................. 8419
4.3 Removing and installing lane change assist warning lamp in exterior mirror -K233-/-K234-.................................................................................................................................................................................................................................................................................................................................................................. 8419
4.3.1 Removing and installing lane change assist warning lamp in exterior mirror -K233-/-K234- - vehicles up to 05.2009................................................................................................................................................................................................................................................................................................................................... 8419
4.3.2 Removing and installing lane change assist warning lamp in exterior mirror -K233-/-K234- - vehicles from 06.2009 onwards............................................................................................................................................................................................................................................................................................................................ 8420
4.4 Removing and installing lane change assist control unit -J769-/-J770-..................................................................................................................................................................................................................................................................................................................................................................................... 8421
4.4.1 Removing and installing lane change assist control unit -J769-/-J770- - Coupé....................................................................................................................................................................................................................................................................................................................................................................... 8421
4.4.2 Removing and installing lane change assist control unit -J769-/-J770- - Sportback................................................................................................................................................................................................................................................................................................................................................................... 8422
4.5 Calibrating lane change assist............................................................................................................................................................................................................................................................................................................................................................................................................................ 8422
4.5.1 Calibrating lane change assist - test equipment layout.............................................................................................................................................................................................................................................................................................................................................................................................. 8422
4.5.2 Calibrating lane change assist control unit -J769-/-J770-........................................................................................................................................................................................................................................................................................................................................................................................... 8423
5 Front camera for driver assist systems.......................................................................................................................................................................................................................................................................................................................................................................................................................... 8430
5.1 Exploded view - main beam assist system, humidity sender and lane departure warning system................................................................................................................................................................................................................................................................................................................................................................ 8430
6 Towing bracket.................................................................................................................................................................................................................................................................................................................................................................................................................................................. 8432
6.1 Overview - trailer socket, trailer detector control unit.................................................................................................................................................................................................................................................................................................................................................................................................. 8432
6.2 Trailer socket............................................................................................................................................................................................................................................................................................................................................................................................................................................ 8432
6.3 Removing and installing trailer detector control unit -J345-.............................................................................................................................................................................................................................................................................................................................................................................................. 8432
7 Cigarette lighter, socket....................................................................................................................................................................................................................................................................................................................................................................................................................................... 8434
7.1 Exploded view - cigarette lighter, 12 V socket............................................................................................................................................................................................................................................................................................................................................................................................................ 8434
7.2 Removing and installing cigarette lighter -U1-............................................................................................................................................................................................................................................................................................................................................................................................................ 8435
7.3 Removing and installing socket illumination bulb -L42-.................................................................................................................................................................................................................................................................................................................................................................................................... 8437
7.3.1 Removing and installing socket illumination bulb -L42-.............................................................................................................................................................................................................................................................................................................................................................................................. 8437
7.3.2 Removing and installing socket illumination bulb -L42-, 12 V socket -U5-............................................................................................................................................................................................................................................................................................................................................................................ 8437
7.4 Removing and installing cigarette lighter illumination bulb -L28-......................................................................................................................................................................................................................................................................................................................................................................................... 8439
7.5 Removing and installing 12 V socket 2 -U18-............................................................................................................................................................................................................................................................................................................................................................................................................... 8439
7.6 Removing and installing AC/DC converter with socket, 12 V - 230 V -U13-................................................................................................................................................................................................................................................................................................................................................................................... 8441
7.7 Removing and installing 12 V socket 3 -U19-............................................................................................................................................................................................................................................................................................................................................................................................................... 8442
7.8 Renewing 12 V socket 3 -U19-.............................................................................................................................................................................................................................................................................................................................................................................................................................. 8442
97 – Wiring........................................................................................................................................................................................................................................................................................................................................................................................................................................................... 8444
1 Relay carriers, fuse carriers, electronics boxes................................................................................................................................................................................................................................................................................................................................................................................................................ 8444
1.1 Overview of fitting locations - relay carriers, fuse carriers, electronics boxes.......................................................................................................................................................................................................................................................................................................................................................................... 8444
1.1.1 Overview - engine compartment electronics box, wiring junction, battery fuse holder................................................................................................................................................................................................................................................................................................................................................................. 8444
1.1.2 Overview - relay carrier/fuse carrier (dash panel), relay carrier/fuse carrier (A-pillar)........................................................................................................................................................................................................................................................................................................................................................... 8446
1.1.3 Overview - relay carrier/fuse carrier (luggage compartment), control units, Coupé................................................................................................................................................................................................................................................................................................................................................................... 8448
1.1.4 Overview - relay carrier/fuse carrier (luggage compartment), control units, Sportback............................................................................................................................................................................................................................................................................................................................................................... 8451
1.2 Removing and installing electronics box................................................................................................................................................................................................................................................................................................................................................................................................................... 8453
1.2.1 Removing and installing electronics box............................................................................................................................................................................................................................................................................................................................................................................................................. 8453
1.2.2 Removing and installing suppression filter -C24-.................................................................................................................................................................................................................................................................................................................................................................................................... 8454
1.3 Removing and installing relay and fuse holder in electronics box.......................................................................................................................................................................................................................................................................................................................................................................................... 8455
1.3.1 Removing and installing fuse holder B -SB- in engine compartment electronics box.................................................................................................................................................................................................................................................................................................................................................................... 8455
1.3.2 Removing and installing fuse carrier in engine compartment electronics box.......................................................................................................................................................................................................................................................................................................................................................................... 8457
1.4 Removing and installing terminal 30 wiring junction 2 -TV22-.............................................................................................................................................................................................................................................................................................................................................................................................. 8458
1.5 Removing and installing fuse holder at dash panel (right-side)............................................................................................................................................................................................................................................................................................................................................................................................ 8459
1.5.1 Removing and installing fuse holder D -SD- with fuse carrier in dash panel (right-side)............................................................................................................................................................................................................................................................................................................................................................. 8459
1.5.2 Removing and installing fuse carrier in dash panel (right-side)..................................................................................................................................................................................................................................................................................................................................................................................... 8460
1.6 Removing and installing relay and fuse carrier behind dash panel (driver's side).......................................................................................................................................................................................................................................................................................................................................................................... 8461
1.6.1 Removing and installing 3-position relay and fuse carrier........................................................................................................................................................................................................................................................................................................................................................................................... 8461
1.6.2 Removing and installing 4-position relay and fuse carrier with screw connection..................................................................................................................................................................................................................................................................................................................................................................... 8462
1.6.3 Removing and installing mounting for relay and fuse carrier with onboard supply control unit -J519-................................................................................................................................................................................................................................................................................................................................................. 8463
1.7 Removing and installing relay and fuse holder in luggage compartment (right-side)......................................................................................................................................................................................................................................................................................................................................................................... 8464
1.7.1 Removing and installing fuse holder A -SA- in luggage compartment................................................................................................................................................................................................................................................................................................................................................................................... 8464
1.7.2 Removing and installing fuse holder F -SF- in luggage compartment (right-side) - Coupé.............................................................................................................................................................................................................................................................................................................................................................. 8466
1.7.3 Removing and installing fuse carrier in luggage compartment (right-side) - Coupé.................................................................................................................................................................................................................................................................................................................................................................... 8466
1.7.4 Removing and installing fuse holder F -SF- in luggage compartment (right-side) - Sportback.......................................................................................................................................................................................................................................................................................................................................................... 8467
1.7.5 Removing and installing fuse carrier in luggage compartment (right-side) - Sportback................................................................................................................................................................................................................................................................................................................................................................ 8468
1.8 Removing and installing fuse holder in dash panel (left-side)............................................................................................................................................................................................................................................................................................................................................................................................. 8469
1.8.1 Removing and installing fuse holder C -SC- with fuse carrier in dash panel (left-side).............................................................................................................................................................................................................................................................................................................................................................. 8469
1.8.2 Removing and installing fuse carrier in dash panel (left-side)...................................................................................................................................................................................................................................................................................................................................................................................... 8470
2 Control units................................................................................................................................................................................................................................................................................................................................................................................................................................................... 8472
2.1 Exploded view - data bus diagnostic interface............................................................................................................................................................................................................................................................................................................................................................................................................. 8472
2.2 Removing and installing onboard supply control unit -J519-................................................................................................................................................................................................................................................................................................................................................................................................ 8472
2.3 Removing and installing garage door operation control unit................................................................................................................................................................................................................................................................................................................................................................................................ 8474
2.3.1 Removing and installing garage door operation control unit -J530- - vehicles up to model year 2011, USA vehicles up to model year 2012.............................................................................................................................................................................................................................................................................................................. 8474
2.3.2 Removing and installing garage door operation control unit -J530- - vehicles from model year 2012 onwards, USA vehicles from model year 2013 onwards................................................................................................................................................................................................................................................................................................ 8475
2.4 Removing and installing data bus diagnostic interface -J533-.............................................................................................................................................................................................................................................................................................................................................................................................. 8475
2.5 Removing and installing special vehicle control unit -J608-............................................................................................................................................................................................................................................................................................................................................................................................... 8476
2.5.1 Removing and installing special vehicle control unit -J608- - Coupé................................................................................................................................................................................................................................................................................................................................................................................. 8476
3 Connectors...................................................................................................................................................................................................................................................................................................................................................................................................................................................... 8478
3.1 Removing and installing CAN separating connector (right-side)............................................................................................................................................................................................................................................................................................................................................................................................. 8478
3.1.1 Removing and installing CAN separating connector (dash panel) -T46s-................................................................................................................................................................................................................................................................................................................................................................................ 8478
3.1.2 Removing and installing mounting for CAN separating connector (dash panel) -T46s-................................................................................................................................................................................................................................................................................................................................................................... 8479
3.2 Removing and installing CAN separating connector (left-side).............................................................................................................................................................................................................................................................................................................................................................................................. 8479
3.2.1 Removing and installing CAN separating connector (interior) -T46i-.................................................................................................................................................................................................................................................................................................................................................................................. 8479
3.2.2 Removing and installing mounting for CAN separating connector (interior) -T46i-..................................................................................................................................................................................................................................................................................................................................................................... 8480
3.3 Unplugging door disconnector.............................................................................................................................................................................................................................................................................................................................................................................................................................. 8481
3.4 Removing and installing connector point at A-pillar (left-side)........................................................................................................................................................................................................................................................................................................................................................................................... 8481
3.4.1 Removing and installing 6-position connector point, A-pillar (driver's side)........................................................................................................................................................................................................................................................................................................................................................................ 8481
3.5 Removing and installing connector point at A-pillar (right-side).......................................................................................................................................................................................................................................................................................................................................................................................... 8482
3.5.1 Removing and installing 6-position connector point, A-pillar (passenger's side)..................................................................................................................................................................................................................................................................................................................................................................... 8482
3.6 Repairing electrical wiring harnesses and electrical connectors........................................................................................................................................................................................................................................................................................................................................................................................... 8483
4 Releasing and dismantling connector housings.................................................................................................................................................................................................................................................................................................................................................................................................................... 8484
5 Cleaning contact surfaces....................................................................................................................................................................................................................................................................................................................................................................................................................................... 8485
6 Repairing aerial wires.......................................................................................................................................................................................................................................................................................................................................................................................................................................... 8486
7 Fibre optic cables.............................................................................................................................................................................................................................................................................................................................................................................................................................................. 8487
8 Vehicle diagnostic, testing and information systems............................................................................................................................................................................................................................................................................................................................................................................................................. 8488
Electrical_system__General_information.................................................................................................................................................................................................................................................................................................................................................................................................................................... 8489
27 – Starter, current supply, CCS..................................................................................................................................................................................................................................................................................................................................................................................................................................... 8493
1 Battery......................................................................................................................................................................................................................................................................................................................................................................................................................................................... 8493
1.1 Basic information on the battery.......................................................................................................................................................................................................................................................................................................................................................................................................................... 8493
1.2 Battery types............................................................................................................................................................................................................................................................................................................................................................................................................................................. 8493
1.2.1 Battery -A- with magic eye.......................................................................................................................................................................................................................................................................................................................................................................................................................... 8494
1.2.2 EFB battery......................................................................................................................................................................................................................................................................................................................................................................................................................................... 8494
1.2.3 AGM battery......................................................................................................................................................................................................................................................................................................................................................................................................................................... 8495
1.3 Warnings and safety precautions........................................................................................................................................................................................................................................................................................................................................................................................................................... 8495
1.3.1 Dangers associated with handling batteries.......................................................................................................................................................................................................................................................................................................................................................................................................... 8495
1.3.3 Work on the airbag system........................................................................................................................................................................................................................................................................................................................................................................................................................... 8497
1.4 Battery terminal screw connection......................................................................................................................................................................................................................................................................................................................................................................................................................... 8498
2 Checking battery................................................................................................................................................................................................................................................................................................................................................................................................................................................ 8499
2.1 Test sequence............................................................................................................................................................................................................................................................................................................................................................................................................................................. 8499
2.1.1 Checking battery - vehicles with battery monitor control unit -J367- or energy management control unit -J644- and data bus diagnostic interface -J533-.............................................................................................................................................................................................................................................................................................. 8499
2.1.2 Checking battery - vehicles without battery monitor control unit -J367- or energy management control unit -J644-.................................................................................................................................................................................................................................................................................................................................... 8500
2.2 Visual check.............................................................................................................................................................................................................................................................................................................................................................................................................................................. 8501
2.3 Checking colour indicator of magic eye.................................................................................................................................................................................................................................................................................................................................................................................................................... 8502
2.3.1 Checking 3-colour indicator, up to 03/2008.......................................................................................................................................................................................................................................................................................................................................................................................................... 8502
2.3.2 Checking 2-colour indicator, from 04/2008 onwards................................................................................................................................................................................................................................................................................................................................................................................................... 8503
2.4 Checking battery using vehicle diagnostic tester.......................................................................................................................................................................................................................................................................................................................................................................................................... 8503
2.5 Battery tester with printer -VAS 6161-.................................................................................................................................................................................................................................................................................................................................................................................................................... 8505
2.5.2 Performing battery test using battery tester with printer -VAS 6161-................................................................................................................................................................................................................................................................................................................................................................................ 8506
2.5.3 Performing maintenance test......................................................................................................................................................................................................................................................................................................................................................................................................................... 8507
2.5.4 Performing service test............................................................................................................................................................................................................................................................................................................................................................................................................................. 8508
2.5.5 Performing warranty test............................................................................................................................................................................................................................................................................................................................................................................................................................ 8508
2.5.7 Evaluating test results............................................................................................................................................................................................................................................................................................................................................................................................................................. 8509
2.6 Battery tester with printer -VAS 5097 A-.................................................................................................................................................................................................................................................................................................................................................................................................................. 8510
2.6.2 Battery load test................................................................................................................................................................................................................................................................................................................................................................................................................................... 8511
2.6.3 Table: low temperature test current................................................................................................................................................................................................................................................................................................................................................................................................................. 8513
2.6.4 Results of battery load test........................................................................................................................................................................................................................................................................................................................................................................................................................ 8514
2.6.6 Evaluating test results............................................................................................................................................................................................................................................................................................................................................................................................................................. 8515
2.7 Current draw test......................................................................................................................................................................................................................................................................................................................................................................................................................................... 8515
2.8 Checking no-load voltage of battery, stock vehicles....................................................................................................................................................................................................................................................................................................................................................................................................... 8517
3 Charging battery................................................................................................................................................................................................................................................................................................................................................................................................................................................ 8518
3.1 Battery charger -VAS 5095 A-.............................................................................................................................................................................................................................................................................................................................................................................................................................. 8518
3.1.1 Description of battery charger -VAS 5095 A-......................................................................................................................................................................................................................................................................................................................................................................................................... 8518
3.1.2 Charging battery with battery charger -VAS 5095 A-.................................................................................................................................................................................................................................................................................................................................................................................................. 8519
3.1.3 Charging totally discharged battery with battery charger -VAS 5095 A-............................................................................................................................................................................................................................................................................................................................................................................... 8520
3.1.4 Backup power supply with battery charger -VAS 5095 A-............................................................................................................................................................................................................................................................................................................................................................................................... 8521
3.1.5 Maintenance charging with battery charger -VAS 5095 A-.............................................................................................................................................................................................................................................................................................................................................................................................. 8523
3.2 Battery charger -VAS 5900-................................................................................................................................................................................................................................................................................................................................................................................................................................ 8523
3.2.1 Description of battery charger -VAS 5900-........................................................................................................................................................................................................................................................................................................................................................................................................... 8524
3.2.2 Charging battery with battery charger -VAS 5900-.................................................................................................................................................................................................................................................................................................................................................................................................... 8524
3.2.3 Service charging with battery charger -VAS 5900-.................................................................................................................................................................................................................................................................................................................................................................................................... 8526
3.2.4 Charging totally discharged battery with battery charger -VAS 5900-................................................................................................................................................................................................................................................................................................................................................................................. 8529
3.2.5 Backup power supply with battery charger -VAS 5900-................................................................................................................................................................................................................................................................................................................................................................................................. 8531
3.2.6 Maintenance charging with battery charger -VAS 5900-................................................................................................................................................................................................................................................................................................................................................................................................ 8534
3.3 Battery charger -VAS 5903-................................................................................................................................................................................................................................................................................................................................................................................................................................ 8535
3.3.1 Description of battery charger -VAS 5903-........................................................................................................................................................................................................................................................................................................................................................................................................... 8536
3.3.2 Charging battery with battery charger -VAS 5903-.................................................................................................................................................................................................................................................................................................................................................................................................... 8536
3.3.3 Charging battery in refresh charge mode with battery charger -VAS 5903-............................................................................................................................................................................................................................................................................................................................................................................. 8538
3.3.4 Charging totally discharged battery with battery charger -VAS 5903-................................................................................................................................................................................................................................................................................................................................................................................. 8541
3.3.5 Backup power supply with battery charger -VAS 5903-................................................................................................................................................................................................................................................................................................................................................................................................. 8543
3.3.6 Maintenance charging with battery charger -VAS 5903-................................................................................................................................................................................................................................................................................................................................................................................................ 8546
3.4 Battery charger -VAS 5906-................................................................................................................................................................................................................................................................................................................................................................................................................................ 8547
3.4.2 Charging battery with battery charger -VAS 5906-.................................................................................................................................................................................................................................................................................................................................................................................................... 8548
3.5 Solar panel -VAS 6102 A-.................................................................................................................................................................................................................................................................................................................................................................................................................................. 8550
3.5.2 Maintenance charging using solar panel -VAS 6102 A-................................................................................................................................................................................................................................................................................................................................................................................................. 8550
3.6 Totally discharged batteries.............................................................................................................................................................................................................................................................................................................................................................................................................................. 8551
4 Alternator...................................................................................................................................................................................................................................................................................................................................................................................................................................................... 8553
4.1 Checking alternator....................................................................................................................................................................................................................................................................................................................................................................................................................................... 8553
4.2 Bosch alternator up to 2000 - exploded view............................................................................................................................................................................................................................................................................................................................................................................................................... 8553
4.3 Bosch alternator from 2001 onwards - exploded view........................................................................................................................................................................................................................................................................................................................................................................................................ 8555
4.4 Removing and installing voltage regulator - Bosch alternator from 2001 onwards............................................................................................................................................................................................................................................................................................................................................................................ 8556
4.5 Bosch alternator from 2007 onwards - exploded view........................................................................................................................................................................................................................................................................................................................................................................................................ 8556
4.6 Removing and installing voltage regulator - Bosch alternator from 2007 onwards............................................................................................................................................................................................................................................................................................................................................................................ 8557
4.7 Checking carbon brushes - all types of Bosch alternators from 2001 onwards................................................................................................................................................................................................................................................................................................................................................................................ 8558
4.8 Valeo alternator up to 2000 - exploded view............................................................................................................................................................................................................................................................................................................................................................................................................... 8558
4.9 Valeo alternator from 2001 onwards - exploded view........................................................................................................................................................................................................................................................................................................................................................................................................ 8560
4.10 Removing and installing voltage regulator - Valeo alternator from 2001 onwards........................................................................................................................................................................................................................................................................................................................................................................... 8561
4.11 Checking carbon brushes - Valeo alternator from 2001 onwards............................................................................................................................................................................................................................................................................................................................................................................................. 8561
4.12 Removing and installing voltage regulator - Valeo alternator from 2007 onwards........................................................................................................................................................................................................................................................................................................................................................................... 8562
4.13 Checking carbon brushes - Valeo alternator from 2007 onwards............................................................................................................................................................................................................................................................................................................................................................................................. 8562
4.14 Removing and installing poly V-belt pulley without free-wheel............................................................................................................................................................................................................................................................................................................................................................................................ 8563
4.15 Removing and installing poly V-belt pulley with free-wheel............................................................................................................................................................................................................................................................................................................................................................................................... 8564
4.16 Checking poly V-belt pulley with free-wheel.............................................................................................................................................................................................................................................................................................................................................................................................................. 8567
92 – Windscreen wash/wipe system...................................................................................................................................................................................................................................................................................................................................................................................................................................... 8568
1 Washer fluid hoses.............................................................................................................................................................................................................................................................................................................................................................................................................................................. 8568
1.1 Disconnecting and connecting washer fluid hose connectors................................................................................................................................................................................................................................................................................................................................................................................................. 8568
1.2 Servicing a smooth washer fluid pipe...................................................................................................................................................................................................................................................................................................................................................................................................................... 8569
1.3 Servicing a washer fluid hose with corrugated tube........................................................................................................................................................................................................................................................................................................................................................................................................ 8570
94 – Lights, bulbs, switches - exterior............................................................................................................................................................................................................................................................................................................................................................................................................................... 8573
1 Safety precautions when handling gas discharge bulbs............................................................................................................................................................................................................................................................................................................................................................................................................ 8573
96 – Lights, bulbs, switches - interior............................................................................................................................................................................................................................................................................................................................................................................................................................... 8575
1 Immobiliser..................................................................................................................................................................................................................................................................................................................................................................................................................................................... 8575
1.1 General notes............................................................................................................................................................................................................................................................................................................................................................................................................................................. 8575
1.2 Defective transponder or loss of key...................................................................................................................................................................................................................................................................................................................................................................................................................... 8575
1.3 Renewing reader coil...................................................................................................................................................................................................................................................................................................................................................................................................................................... 8575
1.4 Procedure for renewing lock set........................................................................................................................................................................................................................................................................................................................................................................................................................... 8576
2 Towing bracket.................................................................................................................................................................................................................................................................................................................................................................................................................................................. 8577
2.1 Removing and installing socket for towing bracket - version 1............................................................................................................................................................................................................................................................................................................................................................................................. 8577
2.2 Removing and installing socket for towing bracket - version 2............................................................................................................................................................................................................................................................................................................................................................................................. 8578
2.3 Removing and installing socket for towing bracket - version 3............................................................................................................................................................................................................................................................................................................................................................................................. 8580
2.4 Removing and installing socket for towing bracket - version 4............................................................................................................................................................................................................................................................................................................................................................................................. 8581
97 – Wiring........................................................................................................................................................................................................................................................................................................................................................................................................................................................... 8584
1 Vehicle diagnostic, testing and information systems............................................................................................................................................................................................................................................................................................................................................................................................................. 8584
1.1 Connecting vehicle diagnostic tester...................................................................................................................................................................................................................................................................................................................................................................................................................... 8584
2 Repairing wiring harnesses and connectors....................................................................................................................................................................................................................................................................................................................................................................................................................... 8586
2.1 General information on repairs to the vehicle electrical system........................................................................................................................................................................................................................................................................................................................................................................................... 8586
2.2 Wiring harness repair set................................................................................................................................................................................................................................................................................................................................................................................................................................. 8589
2.2.1 Wiring harness repair set -VAS 1978-................................................................................................................................................................................................................................................................................................................................................................................................................ 8589
2.2.2 Upgrade kit -VAS 1978/50-........................................................................................................................................................................................................................................................................................................................................................................................................................... 8589
2.2.3 Wiring harness repair set -VAS 1978A-............................................................................................................................................................................................................................................................................................................................................................................................................... 8590
2.2.4 Release tool set -VAS 1978/35-...................................................................................................................................................................................................................................................................................................................................................................................................................... 8590
2.2.5 Wiring harness repair set -VAS 631 001-............................................................................................................................................................................................................................................................................................................................................................................................................. 8590
2.2.6 Wiring harness repair set -VAS 631 003-............................................................................................................................................................................................................................................................................................................................................................................................................. 8591
2.3 Description of tools...................................................................................................................................................................................................................................................................................................................................................................................................................................... 8592
2.3.1 Crimping pliers with insert......................................................................................................................................................................................................................................................................................................................................................................................................................... 8592
2.3.2 Release tools for contacts.......................................................................................................................................................................................................................................................................................................................................................................................................................... 8592
2.3.3 Assembly tools for seals for individual wires....................................................................................................................................................................................................................................................................................................................................................................................................... 8593
2.3.4 Wire strippers -VAS 1978/3-......................................................................................................................................................................................................................................................................................................................................................................................................................... 8593
2.3.6 Crimping pliers -VAS 1978/1A-....................................................................................................................................................................................................................................................................................................................................................................................................................... 8595
2.4 Repairing wiring harnesses................................................................................................................................................................................................................................................................................................................................................................................................................................ 8596
2.4.1 Repairing airbag and belt tensioner wiring.......................................................................................................................................................................................................................................................................................................................................................................................................... 8596
2.4.2 Repairing CAN bus wiring............................................................................................................................................................................................................................................................................................................................................................................................................................ 8599
2.4.3 Repairing FlexRay wiring - with sheath.............................................................................................................................................................................................................................................................................................................................................................................................................. 8599
2.4.4 Repairing FlexRay wiring - without sheath........................................................................................................................................................................................................................................................................................................................................................................................................... 8600
2.4.5 Repairing a wire of 0.22 mm2 section with a single crimp connector.................................................................................................................................................................................................................................................................................................................................................................................. 8601
2.4.6 Repairing a wire of 0.35 mm2 section or thicker with a single crimp connector....................................................................................................................................................................................................................................................................................................................................................................... 8603
2.4.7 Repairing a wire of 0.22 mm2 section by connecting in an additional wire............................................................................................................................................................................................................................................................................................................................................................................ 8605
2.4.8 Repairing a wire of 0.35 mm2 section or thicker by connecting in an additional wire................................................................................................................................................................................................................................................................................................................................................................. 8608
2.4.9 Repairing 10 mm2 or 16 mm2 wiring with single butt connector........................................................................................................................................................................................................................................................................................................................................................................................ 8610
2.4.10 Repairing 2.5 mm2, 4 mm2 or 6 mm2 aluminium wiring with single butt connector...................................................................................................................................................................................................................................................................................................................................................................... 8614
2.5 Repairing fibre optic cables.............................................................................................................................................................................................................................................................................................................................................................................................................................. 8619
2.5.1 Determining location of fault....................................................................................................................................................................................................................................................................................................................................................................................................................... 8619
2.5.2 Preparing fibre optic cables with fibre-optic conductor repair set -VAS 6223-....................................................................................................................................................................................................................................................................................................................................................................... 8620
2.5.3 Preparing fibre optic cables with fibre-optic conductor repair set -VAS 6223A-...................................................................................................................................................................................................................................................................................................................................................................... 8624
2.5.4 Separating fibre optic cable from wiring harness connector.......................................................................................................................................................................................................................................................................................................................................................................................... 8629
2.6 Repairing aerial wires.................................................................................................................................................................................................................................................................................................................................................................................................................................... 8630
2.6.1 Repair set, aerial cable VAS 6720................................................................................................................................................................................................................................................................................................................................................................................................................... 8630
2.6.2 Renewing an entire aerial wire...................................................................................................................................................................................................................................................................................................................................................................................................................... 8640
2.7 Repairing connector housings and electrical connectors.................................................................................................................................................................................................................................................................................................................................................................................................... 8642
2.7.1 Notes on repairing connector housings and electrical connectors..................................................................................................................................................................................................................................................................................................................................................................................... 8642
2.7.2 Repairing contacts in connector housings............................................................................................................................................................................................................................................................................................................................................................................................................ 8643
2.7.3 Fitting seals for individual wires.................................................................................................................................................................................................................................................................................................................................................................................................................. 8644
2.7.4 Repairing connector housings with insulation displacement technology (IDC).......................................................................................................................................................................................................................................................................................................................................................................... 8645
2.8 Releasing and dismantling connector housings.............................................................................................................................................................................................................................................................................................................................................................................................................. 8645
2.8.1 Notes on releasing and dismantling connector housings............................................................................................................................................................................................................................................................................................................................................................................................... 8645
2.8.2 Secondary locking device............................................................................................................................................................................................................................................................................................................................................................................................................................ 8645
2.8.3 Primary locking device.............................................................................................................................................................................................................................................................................................................................................................................................................................. 8646
2.8.4 Round connector systems............................................................................................................................................................................................................................................................................................................................................................................................................................. 8647
2.8.5 Flat connector systems.............................................................................................................................................................................................................................................................................................................................................................................................................................. 8647
2.8.6 Special connector systems........................................................................................................................................................................................................................................................................................................................................................................................................................... 8649
3 Contact surface cleaning set -VAS 6410-......................................................................................................................................................................................................................................................................................................................................................................................................................... 8651
3.1 Using contact surface cleaning set -VAS 6410-............................................................................................................................................................................................................................................................................................................................................................................................................. 8651
3.1.1 Servicing wiring lugs............................................................................................................................................................................................................................................................................................................................................................................................................................... 8651
3.1.2 Servicing screw connections......................................................................................................................................................................................................................................................................................................................................................................................................................... 8653
3.1.3 Cleaning battery terminal clamps and battery terminals.............................................................................................................................................................................................................................................................................................................................................................................................. 8654
3.1.4 Corrosion protection................................................................................................................................................................................................................................................................................................................................................................................................................................ 8656
4 ESD (electrostatic discharge) workplace VAS 6613................................................................................................................................................................................................................................................................................................................................................................................................................ 8658
4.1 Using ESD workplace -VAS 6613-............................................................................................................................................................................................................................................................................................................................................................................................................................ 8658
Fitting_instructions__Filling_roof_side_member_with_foam.................................................................................................................................................................................................................................................................................................................................................................................................................. 8659
51 – Body - centre.................................................................................................................................................................................................................................................................................................................................................................................................................................................... 8663
1 Filling roof side member with foam.............................................................................................................................................................................................................................................................................................................................................................................................................................. 8663
1.1 Sequence of operations.................................................................................................................................................................................................................................................................................................................................................................................................................................... 8663
1.2 The sequence of operations shown must always be observed:................................................................................................................................................................................................................................................................................................................................................................................................. 8663
1.3 Working instructions: Preparation......................................................................................................................................................................................................................................................................................................................................................................................................................... 8664
1.4 Working instructions: Filling with foam................................................................................................................................................................................................................................................................................................................................................................................................................... 8669
Fitting_instructions__radio_communication_systems......................................................................................................................................................................................................................................................................................................................................................................................................................... 8684
91 – Radio, telephone, navigation..................................................................................................................................................................................................................................................................................................................................................................................................................................... 8688
1 Service installation of radio communication systems............................................................................................................................................................................................................................................................................................................................................................................................................. 8688
1.1 General notes............................................................................................................................................................................................................................................................................................................................................................................................................................................. 8688
1.2 Transmission power and possible fitting locations......................................................................................................................................................................................................................................................................................................................................................................................................... 8688
1.3 Voltage supply............................................................................................................................................................................................................................................................................................................................................................................................................................................ 8688
1.4 Aerial and aerial wire.................................................................................................................................................................................................................................................................................................................................................................................................................................... 8689
1.5 Other auxiliary equipment................................................................................................................................................................................................................................................................................................................................................................................................................................. 8689
1.6 Overview of battery -A- / transmitter and receiver unit / fuse / wiring harness........................................................................................................................................................................................................................................................................................................................................................................... 8689
1.7 Transmission power levels and aerial fitting locations for A1 (from model year 2011 up to model year 2012)................................................................................................................................................................................................................................................................................................................................................ 8690
1.8 Transmission power levels and aerial fitting locations for A1 (from model year 2013 onwards).............................................................................................................................................................................................................................................................................................................................................................. 8691
1.9 Transmission power levels and aerial fitting locations for A2 (from model year 2001 onwards).............................................................................................................................................................................................................................................................................................................................................................. 8691
1.10 Transmission power levels and aerial fitting locations for A3 (from model year 1997 up to model year 2003)............................................................................................................................................................................................................................................................................................................................................... 8692
1.11 Transmission power levels and aerial fitting locations for A3 (from model year 2004 up to model year 2012)............................................................................................................................................................................................................................................................................................................................................... 8693
1.12 Transmission power levels and aerial fitting locations for A3, A3 Sportback (from model year 2013 up to week 29/2013).................................................................................................................................................................................................................................................................................................................................... 8693
1.13 Transmission power levels and aerial fitting locations for A3, A3 Sportback, A3 Saloon (from week 30/2013 onwards)....................................................................................................................................................................................................................................................................................................................................... 8694
1.14 Transmission power levels and aerial fitting locations for A3 Cabriolet (from model year 2008 up to model year 2014)..................................................................................................................................................................................................................................................................................................................................... 8694
1.15 Transmission power levels and aerial fitting locations for A3 Cabriolet (from model year 2015 onwards)................................................................................................................................................................................................................................................................................................................................................... 8695
1.16 Transmission power levels and aerial fitting locations for A4 (from model year 1995 up to model year 2000)............................................................................................................................................................................................................................................................................................................................................... 8696
1.17 Transmission power levels and aerial fitting locations for A4 (from model year 2001 up to model year 2007)............................................................................................................................................................................................................................................................................................................................................... 8697
1.18 Transmission power levels and aerial fitting locations for A4 (from model year 2008 up to week 10/2012).................................................................................................................................................................................................................................................................................................................................................. 8699
1.19 Transmission power levels and aerial fitting locations for A4 (from week 11/2012 up to model year 2015).................................................................................................................................................................................................................................................................................................................................................. 8700
1.20 Transmission power levels and aerial fitting locations for A4 (from model year 2016 onwards)............................................................................................................................................................................................................................................................................................................................................................. 8701
1.21 Transmission power levels and aerial fitting locations for A4 Cabriolet (from model year 2003 onwards)................................................................................................................................................................................................................................................................................................................................................... 8702
1.22 Transmission power levels and aerial fitting locations for A5 Coupé (from model year 2008 up to week 10/2012)............................................................................................................................................................................................................................................................................................................................................ 8703
1.23 Transmission power levels and aerial fitting locations for A5 Coupé (from week 11/2012 onwards).......................................................................................................................................................................................................................................................................................................................................................... 8703
1.24 Transmission power levels and aerial fitting locations for A5 Sportback (from model year 2010 up to week 10/2012)........................................................................................................................................................................................................................................................................................................................................ 8704
1.25 Transmission power levels and aerial fitting locations for A5 Sportback (from week 11/2012 onwards)...................................................................................................................................................................................................................................................................................................................................................... 8704
1.26 Transmission power levels and aerial fitting locations for A5 Cabriolet (from model year 2009 up to week 10/2012)........................................................................................................................................................................................................................................................................................................................................ 8705
1.27 Transmission power levels and aerial fitting locations for A5 Cabriolet (from week 11/2012 onwards)...................................................................................................................................................................................................................................................................................................................................................... 8705
1.28 Transmission power levels and aerial fitting locations for A6 (from model year 1998 up to model year 2004)............................................................................................................................................................................................................................................................................................................................................... 8706
1.29 Transmission power levels and aerial fitting locations for A6 (from model year 2005 up to model year 2010)............................................................................................................................................................................................................................................................................................................................................... 8707
1.30 Transmission power levels and aerial fitting locations for A6 (from model year 2011 up to model year 2012)............................................................................................................................................................................................................................................................................................................................................... 8708
1.31 Transmission power levels and aerial fitting locations for A6 (from model year 2013 up to model year 2014)............................................................................................................................................................................................................................................................................................................................................... 8709
1.32 Transmission power levels and aerial fitting locations for A6 (from model year 2015 onwards)............................................................................................................................................................................................................................................................................................................................................................. 8710
1.33 Transmission power levels and aerial fitting locations for A7 Sportback (from model year 2011 up to model year 2012)..................................................................................................................................................................................................................................................................................................................................... 8712
1.34 Transmission power levels and aerial fitting locations for A7 Sportback (from model year 2013 up to model year 2014)..................................................................................................................................................................................................................................................................................................................................... 8712
1.35 Transmission power levels and aerial fitting locations for A7 Sportback (from model year 2015 onwards)................................................................................................................................................................................................................................................................................................................................................... 8713
1.36 Transmission power levels and aerial fitting locations for A8 (from model year 1994 up to model year 2002)............................................................................................................................................................................................................................................................................................................................................... 8714
1.37 Transmission power levels and aerial fitting locations for A8 (from model year 2003 up to model year 2009)............................................................................................................................................................................................................................................................................................................................................... 8714
1.38 Transmission power levels and aerial fitting locations for A8 (from model year 2010 up to model year 2012)............................................................................................................................................................................................................................................................................................................................................... 8715
1.39 Transmission power levels and aerial fitting locations for A8 (from week 22/2012 up to week 35/2013)..................................................................................................................................................................................................................................................................................................................................................... 8715
1.40 Transmission power levels and aerial fitting locations for A8 (from week 36/2013 onwards)................................................................................................................................................................................................................................................................................................................................................................ 8716
1.41 Transmission power levels and aerial fitting locations for Q3 (from model year 2012 up to model year 2014)............................................................................................................................................................................................................................................................................................................................................... 8717
1.42 Transmission power levels and aerial fitting locations for Q3 (from model year 2015 onwards)............................................................................................................................................................................................................................................................................................................................................................. 8717
1.43 Transmission power levels and aerial fitting locations for Q5 (from model year 2008 up to model year 2012)............................................................................................................................................................................................................................................................................................................................................... 8718
1.44 Transmission power levels and aerial fitting locations for Q5 (from model year 2013 onwards)............................................................................................................................................................................................................................................................................................................................................................. 8718
1.45 Transmission power levels and aerial fitting locations for Q7 (from model year 2007 up to model year 2012)............................................................................................................................................................................................................................................................................................................................................... 8719
1.46 Transmission power levels and aerial fitting locations for Q7 (from model year 2013 up to model year 2015)............................................................................................................................................................................................................................................................................................................................................... 8719
1.47 Transmission power levels and aerial fitting locations for Q7 (from model year 2016 onwards)............................................................................................................................................................................................................................................................................................................................................................. 8720
1.48 Transmission power levels and aerial fitting locations for R8 (from model year 2007 up to model year 2015)............................................................................................................................................................................................................................................................................................................................................... 8720
1.49 Transmission power levels and aerial fitting locations for R8 Spyder (from model year 2010 onwards)...................................................................................................................................................................................................................................................................................................................................................... 8721
1.50 Transmission power levels and aerial fitting locations for R8 (from model year 2016 onwards)............................................................................................................................................................................................................................................................................................................................................................. 8721
1.51 Transmission power levels and aerial fitting locations for TT (from model year 1999 up to model year 2006)............................................................................................................................................................................................................................................................................................................................................... 8722
1.52 Transmission power levels and aerial fitting locations for TT (from model year 2007 up to model year 2014)............................................................................................................................................................................................................................................................................................................................................... 8723
1.53 Transmission power levels and aerial fitting locations for TT (from model year 2015 onwards)............................................................................................................................................................................................................................................................................................................................................................. 8724
Fuel_supply_system__diesel_engines........................................................................................................................................................................................................................................................................................................................................................................................................................................ 8726
00 – Technical data................................................................................................................................................................................................................................................................................................................................................................................................................................................... 8730
1 Safety precautions.............................................................................................................................................................................................................................................................................................................................................................................................................................................. 8730
1.1 Safety precautions when working on the fuel system........................................................................................................................................................................................................................................................................................................................................................................................................ 8730
1.2 Safety precautions when working on vehicles with start/stop system........................................................................................................................................................................................................................................................................................................................................................................................ 8731
1.3 Safety precautions when using testers and measuring instruments during a road test........................................................................................................................................................................................................................................................................................................................................................................ 8732
1.4 Safety precautions when working on the SCR system......................................................................................................................................................................................................................................................................................................................................................................................................... 8732
2 Repair instructions............................................................................................................................................................................................................................................................................................................................................................................................................................................. 8734
2.1 Rules for cleanliness..................................................................................................................................................................................................................................................................................................................................................................................................................................... 8734
2.2 Test conditions........................................................................................................................................................................................................................................................................................................................................................................................................................................... 8734
2.3 Contact corrosion......................................................................................................................................................................................................................................................................................................................................................................................................................................... 8734
2.4 Routing and attachment of pipes, hoses and wiring......................................................................................................................................................................................................................................................................................................................................................................................................... 8735
20 – Fuel supply system............................................................................................................................................................................................................................................................................................................................................................................................................................................... 8736
1 Fuel tank....................................................................................................................................................................................................................................................................................................................................................................................................................................................... 8736
1.1 Exploded view - fuel tank................................................................................................................................................................................................................................................................................................................................................................................................................................. 8736
1.1.1 Exploded view - fuel tank, vehicles with front-wheel drive.......................................................................................................................................................................................................................................................................................................................................................................................... 8736
1.1.2 Exploded view - fuel tank, vehicles with four-wheel drive........................................................................................................................................................................................................................................................................................................................................................................................... 8738
1.2 Draining fuel tank........................................................................................................................................................................................................................................................................................................................................................................................................................................ 8741
1.3 Removing and installing fuel tank......................................................................................................................................................................................................................................................................................................................................................................................................................... 8743
1.3.1 Removing and installing fuel tank - vehicles with front-wheel drive................................................................................................................................................................................................................................................................................................................................................................................. 8743
1.3.2 Removing and installing fuel tank - vehicles with four-wheel drive.................................................................................................................................................................................................................................................................................................................................................................................. 8751
1.4 Removing and installing misfuelling prevention device..................................................................................................................................................................................................................................................................................................................................................................................................... 8759
2 Fuel delivery unit/fuel gauge senders........................................................................................................................................................................................................................................................................................................................................................................................................................... 8762
2.1 Exploded view - fuel delivery unit/fuel gauge senders..................................................................................................................................................................................................................................................................................................................................................................................................... 8762
2.1.1 Exploded view - fuel delivery unit and fuel gauge sender, A5 up to model year 2011, A4 up to model year 2012 (vehicles with front-wheel drive)...................................................................................................................................................................................................................................................................................................... 8762
2.1.2 Exploded view - fuel delivery unit and fuel gauge sender, A5 from model year 2012 onwards, A4 from model year 2013 onwards (vehicles with front-wheel drive)........................................................................................................................................................................................................................................................................................ 8764
2.1.3 Exploded view - fuel delivery unit and fuel gauge senders, A5 up to model year 2011, A4 up to model year 2012 (vehicles with four-wheel drive)...................................................................................................................................................................................................................................................................................................... 8766
2.1.4 Exploded view - fuel delivery unit and fuel gauge senders, A5 from model year 2012 onwards, A4 from model year 2013 onwards (vehicles with four-wheel drive)........................................................................................................................................................................................................................................................................................ 8768
2.2 Removing and installing fuel delivery unit/fuel gauge sender.............................................................................................................................................................................................................................................................................................................................................................................................. 8770
2.2.1 Removing and installing fuel delivery unit - A5 up to model year 2011, A4 up to model year 2012 (vehicles with front-wheel drive)................................................................................................................................................................................................................................................................................................................... 8770
2.2.2 Removing and installing fuel delivery unit - A5 from model year 2012 onwards, A4 from model year 2013 onwards (vehicles with front-wheel drive)..................................................................................................................................................................................................................................................................................................... 8776
2.2.3 Removing and installing fuel delivery unit - A5 up to model year 2011, A4 up to model year 2012 (vehicles with four-wheel drive).................................................................................................................................................................................................................................................................................................................... 8782
2.2.4 Removing and installing fuel delivery unit - A5 from model year 2012 onwards, A4 from model year 2013 onwards (vehicles with four-wheel drive)...................................................................................................................................................................................................................................................................................................... 8788
2.3 Checking fuel gauge sender -G-............................................................................................................................................................................................................................................................................................................................................................................................................................ 8794
2.3.1 Checking fuel gauge sender -G- - A5 up to model year 2011, A4 up to model year 2012 (vehicles with front-wheel drive)............................................................................................................................................................................................................................................................................................................................... 8794
2.3.2 Checking fuel gauge sender -G- - A5 from model year 2012 onwards, A4 from model year 2013 onwards (vehicles with front-wheel drive)................................................................................................................................................................................................................................................................................................................. 8796
2.3.3 Checking fuel gauge sender -G- - A5 up to model year 2011, A4 up to model year 2012 (vehicles with four-wheel drive)................................................................................................................................................................................................................................................................................................................................ 8799
2.3.4 Checking fuel gauge sender -G- - A5 from model year 2012 onwards, A4 from model year 2013 onwards (vehicles with four-wheel drive).................................................................................................................................................................................................................................................................................................................. 8801
2.4 Removing and installing fuel gauge sender -G-............................................................................................................................................................................................................................................................................................................................................................................................................. 8804
2.4.1 Removing and installing fuel gauge sender -G- - A5 models up to model year 2011, A4 models up to model year 2012 (vehicles with front-wheel drive).................................................................................................................................................................................................................................................................................................. 8804
2.4.2 Removing and installing fuel gauge sender -G- - A5 models from model year 2012 onwards, A4 models from model year 2013 onwards (vehicles with front-wheel drive).................................................................................................................................................................................................................................................................................... 8805
2.4.3 Removing and installing fuel gauge sender -G- - A5 models up to model year 2011, A4 models up to model year 2012 (vehicles with four-wheel drive)................................................................................................................................................................................................................................................................................................... 8806
2.4.4 Removing and installing fuel gauge sender -G- - A5 models from model year 2012 onwards, A4 models from model year 2013 onwards (vehicles with four-wheel drive)..................................................................................................................................................................................................................................................................................... 8807
2.5 Checking fuel gauge sender 2 -G169-....................................................................................................................................................................................................................................................................................................................................................................................................................... 8808
2.5.1 Checking fuel gauge sender 2 -G169- - A5 up to model year 2011, A4 up to model year 2012 (vehicles with four-wheel drive)........................................................................................................................................................................................................................................................................................................................... 8808
2.5.2 Checking fuel gauge sender 2 -G169- - A5 from model year 2012 onwards, A4 from model year 2013 onwards (vehicles with four-wheel drive)............................................................................................................................................................................................................................................................................................................. 8810
2.6 Removing and installing fuel gauge sender 2 -G169-........................................................................................................................................................................................................................................................................................................................................................................................................ 8813
2.6.1 Removing and installing fuel gauge sender 2 -G169- - A5 up to model year 2011, A4 up to model year 2012 (vehicles with four-wheel drive)............................................................................................................................................................................................................................................................................................................ 8813
2.6.2 Removing and installing fuel gauge sender 2 -G169- - A5 from model year 2012 onwards, A4 from model year 2013 onwards (vehicles with four-wheel drive).............................................................................................................................................................................................................................................................................................. 8818
3 Fuel cooler..................................................................................................................................................................................................................................................................................................................................................................................................................................................... 8824
3.1 Exploded view - fuel cooler............................................................................................................................................................................................................................................................................................................................................................................................................................... 8824
3.2 Removing and installing fuel cooler....................................................................................................................................................................................................................................................................................................................................................................................................................... 8824
4 Fuel filter..................................................................................................................................................................................................................................................................................................................................................................................................................................................... 8826
4.1 Exploded view - fuel filter............................................................................................................................................................................................................................................................................................................................................................................................................................... 8826
4.2 Removing and installing fuel filter....................................................................................................................................................................................................................................................................................................................................................................................................................... 8828
4.3 Removing and installing regulating valve.................................................................................................................................................................................................................................................................................................................................................................................................................. 8829
5 Accelerator mechanism........................................................................................................................................................................................................................................................................................................................................................................................................................................... 8831
5.1 Exploded view - accelerator pedal module.................................................................................................................................................................................................................................................................................................................................................................................................................. 8831
5.2 Removing and installing accelerator pedal module with accelerator position sender -G79-/-G185-............................................................................................................................................................................................................................................................................................................................................................ 8832
6 Checking fuel system for leaks.................................................................................................................................................................................................................................................................................................................................................................................................................................. 8833
7 Fuel pump....................................................................................................................................................................................................................................................................................................................................................................................................................................................... 8834
7.1 Checking fuel system pressurisation pump -G6-............................................................................................................................................................................................................................................................................................................................................................................................................. 8834
7.1.1 Checking fuel delivery rate of fuel system pressurisation pump -G6- (in fuel tank) - A5 up to model year 2011, A4 up to model year 2012 (vehicles with front-wheel drive)........................................................................................................................................................................................................................................................................... 8834
7.1.2 Checking fuel delivery rate of fuel system pressurisation pump -G6- - A5 up to model year 2011, A4 up to model year 2012 (vehicles with four-wheel drive)........................................................................................................................................................................................................................................................................................... 8838
7.1.3 Checking fuel system pressurisation pump -G6- (in fuel tank) - A5 from model year 2012 onwards, A4 from model year 2013 onwards (vehicles with front-wheel drive and vehicles with four-wheel drive)................................................................................................................................................................................................................................................ 8842
7.1.4 Checking fuel system pressurisation pump -G6- (electrical test) - A5 up to model year 2011, A4 up to model year 2012 (vehicles with front-wheel drive).............................................................................................................................................................................................................................................................................................. 8848
7.1.5 Checking fuel system pressurisation pump -G6- (electrical test) - A5 up to model year 2011, A4 up to model year 2012 (vehicles with four-wheel drive)............................................................................................................................................................................................................................................................................................... 8851
7.1.6 Checking fuel system pressurisation pump -G6- (electrical test) - A5 from model year 2012 onwards, A4 from model year 2013 onwards (vehicles with front-wheel drive and vehicles with four-wheel drive)............................................................................................................................................................................................................................................. 8854
7.2 Exploded view - supplementary fuel pump -V393-............................................................................................................................................................................................................................................................................................................................................................................................................ 8854
7.3 Checking delivery rate of supplementary fuel pump -V393-.................................................................................................................................................................................................................................................................................................................................................................................................. 8856
7.4 Removing and installing fuel pump......................................................................................................................................................................................................................................................................................................................................................................................................................... 8858
7.4.1 Removing and installing supplementary fuel pump -V393-.............................................................................................................................................................................................................................................................................................................................................................................................. 8858
7.5 Removing and installing suction pipe...................................................................................................................................................................................................................................................................................................................................................................................................................... 8860
7.6 Removing and installing fuel pump control unit -J538-..................................................................................................................................................................................................................................................................................................................................................................................................... 8862
7.6.1 Removing and installing fuel pump control unit -J538- - vehicles with front-wheel drive............................................................................................................................................................................................................................................................................................................................................................. 8862
7.6.2 Removing and installing fuel pump control unit -J538- - vehicles with four-wheel drive.............................................................................................................................................................................................................................................................................................................................................................. 8867
7.7 Checking fuel pump control unit - J538-................................................................................................................................................................................................................................................................................................................................................................................................................... 8872
7.7.1 Checking fuel pump control unit -J538- - vehicles with front-wheel drive............................................................................................................................................................................................................................................................................................................................................................................ 8872
7.7.2 Checking fuel pump control unit -J538- - vehicles with four-wheel drive............................................................................................................................................................................................................................................................................................................................................................................. 8872
Fuel_supply_system__petrol_engines........................................................................................................................................................................................................................................................................................................................................................................................................................................ 8873
00 – Technical data................................................................................................................................................................................................................................................................................................................................................................................................................................................... 8877
1 Safety precautions.............................................................................................................................................................................................................................................................................................................................................................................................................................................. 8877
1.1 Safety precautions when working on the fuel system........................................................................................................................................................................................................................................................................................................................................................................................................ 8877
1.2 Safety precautions when using testers and measuring instruments during a road test........................................................................................................................................................................................................................................................................................................................................................................ 8879
2 Repair instructions............................................................................................................................................................................................................................................................................................................................................................................................................................................. 8880
2.1 Rules for cleanliness..................................................................................................................................................................................................................................................................................................................................................................................................................................... 8880
2.2 Test conditions........................................................................................................................................................................................................................................................................................................................................................................................................................................... 8880
2.3 Contact corrosion......................................................................................................................................................................................................................................................................................................................................................................................................................................... 8880
20 – Fuel supply system............................................................................................................................................................................................................................................................................................................................................................................................................................................... 8882
1 Fuel tank....................................................................................................................................................................................................................................................................................................................................................................................................................................................... 8882
1.1 Exploded view - fuel tank................................................................................................................................................................................................................................................................................................................................................................................................................................. 8882
1.1.1 Exploded view - fuel tank, rest-of-world vehicles with front-wheel drive............................................................................................................................................................................................................................................................................................................................................................................ 8882
1.1.2 Exploded view - fuel tank, rest-of-world vehicles with four-wheel drive............................................................................................................................................................................................................................................................................................................................................................................. 8884
1.1.3 Exploded view - fuel tank, USA vehicles with front-wheel drive/four-wheel drive..................................................................................................................................................................................................................................................................................................................................................................... 8886
1.2 Draining fuel tank........................................................................................................................................................................................................................................................................................................................................................................................................................................ 8887
1.2.1 Draining fuel tank - rest-of-world vehicles with front-wheel drive.................................................................................................................................................................................................................................................................................................................................................................................. 8887
1.2.2 Draining fuel tank - rest-of-world vehicles with four-wheel drive................................................................................................................................................................................................................................................................................................................................................................................... 8889
1.2.3 Draining fuel tank - USA vehicles with front-wheel drive/four-wheel drive........................................................................................................................................................................................................................................................................................................................................................................... 8890
1.3 Removing and installing fuel tank......................................................................................................................................................................................................................................................................................................................................................................................................................... 8892
1.3.1 Removing and installing fuel tank with attached components - rest-of-world vehicles with front-wheel drive.......................................................................................................................................................................................................................................................................................................................................... 8892
1.3.2 Removing and installing fuel tank with attached components - rest-of-world vehicles with four-wheel drive........................................................................................................................................................................................................................................................................................................................................... 8897
1.3.3 Removing and installing fuel tank with attached components - USA vehicles with front-wheel drive/four-wheel drive................................................................................................................................................................................................................................................................................................................................... 8902
2 Fuel delivery unit/fuel gauge senders........................................................................................................................................................................................................................................................................................................................................................................................................................... 8908
2.1 Exploded view - fuel delivery unit/fuel gauge senders..................................................................................................................................................................................................................................................................................................................................................................................................... 8908
2.1.1 Exploded view - fuel delivery unit/fuel gauge sender, A5 up to model year 2011, A4 up to model year 2012, rest-of-world vehicles with front-wheel drive............................................................................................................................................................................................................................................................................................. 8908
2.1.2 Exploded view - fuel delivery unit/fuel gauge sender, A5 from model year 2012 onwards, A4 from model year 2013 onwards, rest-of-world vehicles with front-wheel drive............................................................................................................................................................................................................................................................................... 8910
2.1.3 Exploded view - fuel delivery unit/fuel gauge senders, A5 up to model year 2011, A4 up to model year 2012, rest-of-world vehicles with four-wheel drive, USA vehicles with front-wheel drive/four-wheel drive....................................................................................................................................................................................................................................... 8912
2.1.4 Exploded view - fuel delivery unit/fuel gauge senders, A5 from model year 2012 onwards, A4 from model year 2013 onwards, rest-of-world vehicles with four-wheel drive, USA vehicles with front-wheel drive/four-wheel drive......................................................................................................................................................................................................................... 8914
2.2 Removing and installing fuel delivery unit/fuel gauge sender.............................................................................................................................................................................................................................................................................................................................................................................................. 8916
2.2.1 Removing and installing fuel delivery unit - A5 up to model year 2011, A4 up to model year 2012, rest-of-world vehicles with front-wheel drive...................................................................................................................................................................................................................................................................................................... 8916
2.2.2 Removing and installing fuel delivery unit - A5 from model year 2012 onwards, A4 from model year 2013 onwards, rest-of-world vehicles with front-wheel drive........................................................................................................................................................................................................................................................................................ 8922
2.2.3 Removing and installing fuel delivery unit - A5 up to model year 2011, A4 up to model year 2012, rest-of-world vehicles with four-wheel drive, USA vehicles with front-wheel drive/four-wheel drive................................................................................................................................................................................................................................................. 8928
2.2.4 Removing and installing fuel delivery unit - A5 from model year 2012 onwards, A4 from model year 2013 onwards, rest-of-world vehicles with four-wheel drive, USA vehicles with front-wheel drive/four-wheel drive................................................................................................................................................................................................................................... 8935
2.3 Checking fuel gauge sender -G-............................................................................................................................................................................................................................................................................................................................................................................................................................ 8941
2.3.1 Checking fuel gauge sender -G- - A5 up to model year 2011, A4 up to model year 2012, rest-of-world vehicles with front-wheel drive.................................................................................................................................................................................................................................................................................................................. 8941
2.3.2 Checking fuel gauge sender -G- - A5 from model year 2012 onwards, A4 from model year 2013 onwards, rest-of-world vehicles with front-wheel drive.................................................................................................................................................................................................................................................................................................... 8943
2.3.3 Checking fuel gauge sender -G- - A5 up to model year 2011, A4 up to model year 2012, rest-of-world vehicles with four-wheel drive, USA vehicles with front-wheel drive/four-wheel drive............................................................................................................................................................................................................................................................. 8946
2.3.4 Checking fuel gauge sender -G- - A5 from model year 2012 onwards, A4 from model year 2013 onwards, rest-of-world vehicles with four-wheel drive, USA vehicles with front-wheel drive/four-wheel drive............................................................................................................................................................................................................................................... 8949
2.4 Removing and installing fuel gauge sender -G-............................................................................................................................................................................................................................................................................................................................................................................................................. 8952
2.4.1 Removing and installing fuel gauge sender -G- - A5 up to model year 2011, A4 up to model year 2012, rest-of-world vehicles with front-wheel drive................................................................................................................................................................................................................................................................................................... 8952
2.4.2 Removing and installing fuel gauge sender -G- - A5 from model year 2012 onwards, A4 from model year 2013 onwards, rest-of-world vehicles with front-wheel drive..................................................................................................................................................................................................................................................................................... 8953
2.4.3 Removing and installing fuel gauge sender -G-, A5 up to model year 2011, A4 up to model year 2012, rest-of-world vehicles with four-wheel drive, USA vehicles with front-wheel drive/four-wheel drive............................................................................................................................................................................................................................................... 8954
2.4.4 Removing and installing fuel gauge sender -G- - A5 from model year 2012 onwards, A4 from model year 2013 onwards, rest-of-world vehicles with four-wheel drive, USA vehicles with front-wheel drive/four-wheel drive................................................................................................................................................................................................................................ 8955
2.5 Checking fuel gauge sender 2 -G169-....................................................................................................................................................................................................................................................................................................................................................................................................................... 8956
2.5.1 Checking fuel gauge sender 2 -G169- - A5 up to model year 2011, A4 up to model year 2012, rest-of-world vehicles with four-wheel drive, USA vehicles with front-wheel drive/four-wheel drive........................................................................................................................................................................................................................................................ 8956
2.5.2 Checking fuel gauge sender 2 -G169- - A5 from model year 2012 onwards, A4 from model year 2013 onwards, rest-of-world vehicles with four-wheel drive, USA vehicles with front-wheel drive/four-wheel drive.......................................................................................................................................................................................................................................... 8959
2.6 Removing and installing fuel gauge sender 2 -G169-........................................................................................................................................................................................................................................................................................................................................................................................................ 8963
2.6.1 Removing and installing fuel gauge sender 2 -G169- - A5 up to model year 2011, A4 up to model year 2012, rest-of-world vehicles with four-wheel drive, USA vehicles with front-wheel drive/four-wheel drive......................................................................................................................................................................................................................................... 8963
2.6.2 Removing and installing fuel gauge sender 2 -G169- - A5 from model year 2012 onwards, A4 from model year 2013 onwards, rest-of-world vehicles with four-wheel drive, USA vehicles with front-wheel drive/four-wheel drive........................................................................................................................................................................................................................... 8969
3 Plug-in connectors.............................................................................................................................................................................................................................................................................................................................................................................................................................................. 8975
3.1 Disconnecting plug-in connectors.......................................................................................................................................................................................................................................................................................................................................................................................................................... 8975
4 Fuel filter..................................................................................................................................................................................................................................................................................................................................................................................................................................................... 8979
4.1 Exploded view - fuel filter............................................................................................................................................................................................................................................................................................................................................................................................................................... 8979
4.1.1 Exploded view - fuel filter, A5 up to model year 2011, A4 up to model year 2012..................................................................................................................................................................................................................................................................................................................................................................... 8979
4.1.2 Exploded view - fuel filter, A5 from model year 2012 onwards, A4 from model year 2013 onwards....................................................................................................................................................................................................................................................................................................................................................... 8980
4.2 Removing and installing fuel filter....................................................................................................................................................................................................................................................................................................................................................................................................................... 8981
4.2.1 Removing and installing fuel filter - A5 up to model year 2011, A4 up to model year 2012............................................................................................................................................................................................................................................................................................................................................................ 8981
4.2.2 Removing and installing fuel filter - A5 from model year 2012 onwards, A4 from model year 2013 onwards.............................................................................................................................................................................................................................................................................................................................................. 8982
5 Activated charcoal filter system................................................................................................................................................................................................................................................................................................................................................................................................................................ 8983
5.1 Connection diagram - activated charcoal filter system..................................................................................................................................................................................................................................................................................................................................................................................................... 8983
5.1.1 Connection diagram - activated charcoal filter system with tank leak diagnostic system, vehicles with 4-cylinder engine, USA vehicles............................................................................................................................................................................................................................................................................................................... 8983
5.1.2 Connection diagram - activated charcoal filter system with tank leak diagnostic system, vehicles with 6-cylinder engine, USA vehicles............................................................................................................................................................................................................................................................................................................... 8985
5.1.3 Connection diagram - activated charcoal filter system with tank leak diagnostic system, vehicles with 8-cylinder engine, USA vehicles............................................................................................................................................................................................................................................................................................................... 8986
5.2 Exploded view - activated charcoal filter system.......................................................................................................................................................................................................................................................................................................................................................................................................... 8987
5.2.1 Exploded view - activated charcoal filter system, rest-of-world vehicles............................................................................................................................................................................................................................................................................................................................................................................ 8987
5.2.2 Exploded view - activated charcoal filter system and tank leak diagnostic system, USA vehicles...................................................................................................................................................................................................................................................................................................................................................... 8988
5.3 Removing and installing activated charcoal filter......................................................................................................................................................................................................................................................................................................................................................................................................... 8989
5.3.1 Removing and installing activated charcoal filter - rest-of-world vehicles.......................................................................................................................................................................................................................................................................................................................................................................... 8989
5.3.2 Removing and installing activated charcoal filter - USA vehicles.................................................................................................................................................................................................................................................................................................................................................................................... 8990
5.4 Checking fuel system for leaks............................................................................................................................................................................................................................................................................................................................................................................................................................ 8990
5.4.1 Performing tank leak diagnosis - vehicles up to model year 2012, USA vehicles....................................................................................................................................................................................................................................................................................................................................................................... 8990
5.5 Removing and installing fuel system diagnostic pump....................................................................................................................................................................................................................................................................................................................................................................................................... 8993
5.6 Removing and installing control unit for fuel tank leak detection with integrated tank pressure sensor.................................................................................................................................................................................................................................................................................................................................................... 8993
5.7 Removing and installing air filter for tank leak diagnostic system........................................................................................................................................................................................................................................................................................................................................................................................ 8993
5.8 Tank leak diagnostic system............................................................................................................................................................................................................................................................................................................................................................................................................................... 8994
5.8.1 Tank leak diagnostic system, vehicles up to model year 2012, USA vehicles........................................................................................................................................................................................................................................................................................................................................................................... 8994
5.8.2 Tank leak diagnostic system, vehicles from model year 2013 onwards, USA vehicles.................................................................................................................................................................................................................................................................................................................................................................... 8995
6 Accelerator mechanism........................................................................................................................................................................................................................................................................................................................................................................................................................................... 8996
6.1 Exploded view - accelerator pedal module.................................................................................................................................................................................................................................................................................................................................................................................................................. 8996
6.2 Removing and installing accelerator pedal module with accelerator position sender -G79-/-G185-............................................................................................................................................................................................................................................................................................................................................................ 8997
7 Bleeding fuel system............................................................................................................................................................................................................................................................................................................................................................................................................................................ 8998
7.1 Bleeding fuel system...................................................................................................................................................................................................................................................................................................................................................................................................................................... 8998
7.2 Bleeding fuel supply line leading to metering pump........................................................................................................................................................................................................................................................................................................................................................................................................ 8998
8 Fuel pump....................................................................................................................................................................................................................................................................................................................................................................................................................................................... 9000
8.1 Checking fuel system pressurisation pump -G6-............................................................................................................................................................................................................................................................................................................................................................................................................. 9000
8.1.1 Checking fuel system pressurisation pump -G6- - A5/S5/RS 5 up to model year 2011, A4 up to model year 2012.......................................................................................................................................................................................................................................................................................................................................... 9000
8.1.2 Checking fuel system pressurisation pump -G6- - A5 from model year 2012 onwards, A4 with 4-cyl. and 6-cyl. engines from model year 2013 onwards, RS 5 from model year 2012 onwards, RS 4............................................................................................................................................................................................................................................................ 9009
8.2 Removing and installing suction pipe...................................................................................................................................................................................................................................................................................................................................................................................................................... 9015
8.3 Removing and installing fuel pump control unit -J538-..................................................................................................................................................................................................................................................................................................................................................................................................... 9016
8.3.1 Removing and installing fuel pump control unit -J538- - rest-of-world vehicles with front-wheel drive............................................................................................................................................................................................................................................................................................................................................... 9016
8.3.2 Removing and installing fuel pump control unit -J538- - rest-of-world vehicles with four-wheel drive, USA vehicles with front-wheel drive/four-wheel drive.......................................................................................................................................................................................................................................................................................... 9021
8.4 Checking fuel pump control unit -J538-.................................................................................................................................................................................................................................................................................................................................................................................................................... 9027
8.4.1 Checking fuel pump control unit -J538- - rest-of-world vehicles with front-wheel drive.............................................................................................................................................................................................................................................................................................................................................................. 9027
8.4.2 Checking fuel pump control unit -J538- - rest-of-world vehicles with four-wheel drive, USA vehicles with front-wheel drive/four-wheel drive......................................................................................................................................................................................................................................................................................................... 9027
General_body_repairs__exterior............................................................................................................................................................................................................................................................................................................................................................................................................................................ 9028
00 – Technical data................................................................................................................................................................................................................................................................................................................................................................................................................................................... 9036
1 Notes on repairs................................................................................................................................................................................................................................................................................................................................................................................................................................................ 9036
1.1 Routing and attaching lines and wiring.................................................................................................................................................................................................................................................................................................................................................................................................................... 9036
1.2 Contact corrosion......................................................................................................................................................................................................................................................................................................................................................................................................................................... 9036
1.3 Bonding surfaces for adhesive strips...................................................................................................................................................................................................................................................................................................................................................................................................................... 9036
50 – Body - front..................................................................................................................................................................................................................................................................................................................................................................................................................................................... 9037
1 Lock carrier.................................................................................................................................................................................................................................................................................................................................................................................................................................................... 9037
1.1 Exploded view - lock carrier.............................................................................................................................................................................................................................................................................................................................................................................................................................. 9037
1.2 Setting service position and returning to normal position................................................................................................................................................................................................................................................................................................................................................................................................. 9038
1.3 Removing and installing lock carrier brace................................................................................................................................................................................................................................................................................................................................................................................................................ 9041
1.4 Removing and installing lock carrier cover................................................................................................................................................................................................................................................................................................................................................................................................................ 9042
2 Wing............................................................................................................................................................................................................................................................................................................................................................................................................................................................ 9043
2.1 Removing and installing wing.............................................................................................................................................................................................................................................................................................................................................................................................................................. 9043
2.2 Removing and installing wing panel brace.................................................................................................................................................................................................................................................................................................................................................................................................................. 9044
2.3 Removing and installing seal for wing..................................................................................................................................................................................................................................................................................................................................................................................................................... 9045
2.4 Removing and installing closure plate..................................................................................................................................................................................................................................................................................................................................................................................................................... 9046
3 Bulkhead........................................................................................................................................................................................................................................................................................................................................................................................................................................................ 9047
3.1 Exploded view - plenum chamber partition panel............................................................................................................................................................................................................................................................................................................................................................................................................ 9047
3.2 Removing and installing plenum chamber cover.............................................................................................................................................................................................................................................................................................................................................................................................................. 9048
3.2.1 Removing and installing plenum chamber cover - vehicles up to 05.2008............................................................................................................................................................................................................................................................................................................................................................................... 9048
3.2.2 Removing and installing plenum chamber cover - vehicles from 06.2008 onwards........................................................................................................................................................................................................................................................................................................................................................................ 9050
55 – Bonnet, rear lid................................................................................................................................................................................................................................................................................................................................................................................................................................................. 9051
1 Bonnet.......................................................................................................................................................................................................................................................................................................................................................................................................................................................... 9051
1.1 Exploded view - bonnet.................................................................................................................................................................................................................................................................................................................................................................................................................................... 9051
1.2 Exploded view - bonnet lock............................................................................................................................................................................................................................................................................................................................................................................................................................... 9053
1.3 Exploded view - Bowden cable.............................................................................................................................................................................................................................................................................................................................................................................................................................. 9053
1.4 Exploded view - gas strut................................................................................................................................................................................................................................................................................................................................................................................................................................. 9057
1.5 Exploded view - bonnet seals.............................................................................................................................................................................................................................................................................................................................................................................................................................. 9059
1.6 Adjusting bonnet.......................................................................................................................................................................................................................................................................................................................................................................................................................................... 9059
1.7 Removing and installing operating lever for bonnet lock................................................................................................................................................................................................................................................................................................................................................................................................... 9061
1.8 Removing and installing striker........................................................................................................................................................................................................................................................................................................................................................................................................................... 9062
1.9 Removing and installing hinges............................................................................................................................................................................................................................................................................................................................................................................................................................ 9063
1.10 Removing and installing insulation....................................................................................................................................................................................................................................................................................................................................................................................................................... 9064
1.11 Removing and installing gas strut........................................................................................................................................................................................................................................................................................................................................................................................................................ 9064
1.12 Releasing gas from gas strut............................................................................................................................................................................................................................................................................................................................................................................................................................. 9065
1.13 Removing and installing impact guard..................................................................................................................................................................................................................................................................................................................................................................................................................... 9065
2 Rear lid........................................................................................................................................................................................................................................................................................................................................................................................................................................................ 9067
2.1 Exploded view - rear lid.................................................................................................................................................................................................................................................................................................................................................................................................................................. 9067
2.2 Exploded view - gas strut................................................................................................................................................................................................................................................................................................................................................................................................................................. 9069
2.3 Adjusting rear lid........................................................................................................................................................................................................................................................................................................................................................................................................................................ 9069
2.4 Removing and installing rear lid lock..................................................................................................................................................................................................................................................................................................................................................................................................................... 9073
2.5 Removing and installing hinges............................................................................................................................................................................................................................................................................................................................................................................................................................ 9074
2.6 Manual release for rear lid lock.......................................................................................................................................................................................................................................................................................................................................................................................................................... 9076
2.7 Removing and installing rear lid seal..................................................................................................................................................................................................................................................................................................................................................................................................................... 9077
2.8 Removing and installing gas strut......................................................................................................................................................................................................................................................................................................................................................................................................................... 9078
2.9 Releasing gas from gas strut.............................................................................................................................................................................................................................................................................................................................................................................................................................. 9079
3 Tank flap unit.................................................................................................................................................................................................................................................................................................................................................................................................................................................. 9080
3.1 Exploded view - tank flap unit............................................................................................................................................................................................................................................................................................................................................................................................................................ 9080
3.2 Removing and installing lid for tank flap................................................................................................................................................................................................................................................................................................................................................................................................................. 9081
3.3 Removing and installing tank flap unit.................................................................................................................................................................................................................................................................................................................................................................................................................... 9082
3.4 Gap widths at tank flap................................................................................................................................................................................................................................................................................................................................................................................................................................... 9082
3.5 Removing and installing tank flap cup..................................................................................................................................................................................................................................................................................................................................................................................................................... 9083
3.6 Removing and installing drain hose for tank flap cup...................................................................................................................................................................................................................................................................................................................................................................................................... 9084
3.7 Removing and installing manual release for tank flap...................................................................................................................................................................................................................................................................................................................................................................................................... 9086
57 – Front doors, door components, central locking.................................................................................................................................................................................................................................................................................................................................................................................................................... 9087
1 Door............................................................................................................................................................................................................................................................................................................................................................................................................................................................ 9087
1.1 Exploded view - door...................................................................................................................................................................................................................................................................................................................................................................................................................................... 9087
1.2 Removing and installing door.............................................................................................................................................................................................................................................................................................................................................................................................................................. 9088
1.3 Adjusting door............................................................................................................................................................................................................................................................................................................................................................................................................................................ 9089
1.4 Adjusting striker......................................................................................................................................................................................................................................................................................................................................................................................................................................... 9091
1.5 Removing and installing door arrester..................................................................................................................................................................................................................................................................................................................................................................................................................... 9091
1.6 Removing and installing inner door seal................................................................................................................................................................................................................................................................................................................................................................................................................... 9092
1.7 Removing and installing outer door seal................................................................................................................................................................................................................................................................................................................................................................................................................... 9093
2 Door components................................................................................................................................................................................................................................................................................................................................................................................................................................................. 9099
2.1 Exploded view - window regulator.......................................................................................................................................................................................................................................................................................................................................................................................................................... 9099
2.2 Exploded view - door handle and door lock................................................................................................................................................................................................................................................................................................................................................................................................................. 9100
2.3 Exploded view - window slot trim strips................................................................................................................................................................................................................................................................................................................................................................................................................... 9103
2.4 Removing and installing inner door cover.................................................................................................................................................................................................................................................................................................................................................................................................................. 9104
2.5 Removing and installing window regulator motor............................................................................................................................................................................................................................................................................................................................................................................................................ 9104
2.6 Removing and installing window regulator.................................................................................................................................................................................................................................................................................................................................................................................................................. 9105
2.7 Removing and installing lock cylinder..................................................................................................................................................................................................................................................................................................................................................................................................................... 9107
2.8 Removing and installing cap for lock cylinder............................................................................................................................................................................................................................................................................................................................................................................................................. 9107
2.9 Removing and installing lock cylinder guide............................................................................................................................................................................................................................................................................................................................................................................................................... 9107
2.10 Removing and installing door handle...................................................................................................................................................................................................................................................................................................................................................................................................................... 9108
2.11 Removing and installing door handle trim................................................................................................................................................................................................................................................................................................................................................................................................................. 9109
2.12 Removing and installing contact sensor for front exterior door handle -G605-/-G606-...................................................................................................................................................................................................................................................................................................................................................................... 9110
2.13 Removing and installing door lock........................................................................................................................................................................................................................................................................................................................................................................................................................ 9110
2.14 Removing and installing mounting bracket................................................................................................................................................................................................................................................................................................................................................................................................................. 9112
2.15 Removing and installing operating cable for door lock.................................................................................................................................................................................................................................................................................................................................................................................................... 9113
2.16 Removing and installing operating cable for interior door handle......................................................................................................................................................................................................................................................................................................................................................................................... 9114
2.17 Removing and installing striker.......................................................................................................................................................................................................................................................................................................................................................................................................................... 9115
2.18 Removing and installing outer window slot trim strip..................................................................................................................................................................................................................................................................................................................................................................................................... 9115
3 Central locking system.......................................................................................................................................................................................................................................................................................................................................................................................................................................... 9118
3.1 Overview of fitting locations - central locking system.................................................................................................................................................................................................................................................................................................................................................................................................... 9118
3.2 Removing and installing driver door control unit -J386- and front passenger door control unit -J387-...................................................................................................................................................................................................................................................................................................................................................... 9119
3.3 Removing and installing rear left door control unit -J388- and rear right door control unit -J389-........................................................................................................................................................................................................................................................................................................................................................ 9120
3.4 Removing and installing convenience system central control unit -J393-.................................................................................................................................................................................................................................................................................................................................................................................... 9120
3.5 Removing and installing interface control unit for vehicle location system -J843-......................................................................................................................................................................................................................................................................................................................................................................... 9121
3.6 Removing and installing tank filler flap locking motor -V155-............................................................................................................................................................................................................................................................................................................................................................................................. 9121
58 – Rear doors, door components...................................................................................................................................................................................................................................................................................................................................................................................................................................... 9124
1 Door............................................................................................................................................................................................................................................................................................................................................................................................................................................................ 9124
1.1 Exploded view - door...................................................................................................................................................................................................................................................................................................................................................................................................................................... 9124
1.2 Exploded view - door arrester............................................................................................................................................................................................................................................................................................................................................................................................................................. 9125
1.3 Removing and installing door.............................................................................................................................................................................................................................................................................................................................................................................................................................. 9126
1.4 Adjusting door............................................................................................................................................................................................................................................................................................................................................................................................................................................ 9126
1.5 Adjusting striker......................................................................................................................................................................................................................................................................................................................................................................................................................................... 9128
1.6 Removing and installing door arrester..................................................................................................................................................................................................................................................................................................................................................................................................................... 9129
1.7 Removing and installing inner door seal................................................................................................................................................................................................................................................................................................................................................................................................................... 9129
1.8 Removing and installing outer door seal................................................................................................................................................................................................................................................................................................................................................................................................................... 9131
2 Door components................................................................................................................................................................................................................................................................................................................................................................................................................................................. 9137
2.1 Exploded view - window regulator.......................................................................................................................................................................................................................................................................................................................................................................................................................... 9137
2.2 Exploded view - door handle and door lock................................................................................................................................................................................................................................................................................................................................................................................................................. 9138
2.3 Exploded view - housing................................................................................................................................................................................................................................................................................................................................................................................................................................... 9142
2.4 Exploded view - window slot trim strips................................................................................................................................................................................................................................................................................................................................................................................................................... 9143
2.5 Removing and installing inner door cover.................................................................................................................................................................................................................................................................................................................................................................................................................. 9144
2.6 Removing and installing window regulator motor............................................................................................................................................................................................................................................................................................................................................................................................................ 9145
2.7 Removing and installing window regulator.................................................................................................................................................................................................................................................................................................................................................................................................................. 9146
2.8 Removing and installing housing........................................................................................................................................................................................................................................................................................................................................................................................................................... 9147
2.9 Removing and installing cap for housing................................................................................................................................................................................................................................................................................................................................................................................................................... 9147
2.10 Removing and installing door handle...................................................................................................................................................................................................................................................................................................................................................................................................................... 9147
2.11 Removing and installing door handle trim................................................................................................................................................................................................................................................................................................................................................................................................................. 9149
2.12 Removing and installing contact sensor for rear exterior door handle -G417-/-G418-....................................................................................................................................................................................................................................................................................................................................................................... 9149
2.13 Removing and installing door lock........................................................................................................................................................................................................................................................................................................................................................................................................................ 9150
2.14 Removing and installing mounting bracket................................................................................................................................................................................................................................................................................................................................................................................................................. 9151
2.15 Removing and installing operating cable for door lock.................................................................................................................................................................................................................................................................................................................................................................................................... 9152
2.16 Removing and installing operating cable for interior door handle......................................................................................................................................................................................................................................................................................................................................................................................... 9153
2.17 Removing and installing striker.......................................................................................................................................................................................................................................................................................................................................................................................................................... 9154
2.18 Removing and installing outer window slot trim strip..................................................................................................................................................................................................................................................................................................................................................................................................... 9155
60 – Sunroof.......................................................................................................................................................................................................................................................................................................................................................................................................................................................... 9157
1 Sliding sunroof................................................................................................................................................................................................................................................................................................................................................................................................................................................. 9157
1.1 Exploded view - sliding sunroof........................................................................................................................................................................................................................................................................................................................................................................................................................... 9157
1.2 Removing and installing sunroof panel..................................................................................................................................................................................................................................................................................................................................................................................................................... 9161
1.3 Adjusting sunroof panel................................................................................................................................................................................................................................................................................................................................................................................................................................... 9162
1.4 Removing and installing wind deflector.................................................................................................................................................................................................................................................................................................................................................................................................................... 9162
1.5 Removing and installing sunroof seals..................................................................................................................................................................................................................................................................................................................................................................................................................... 9162
1.6 Removing and installing sun blind......................................................................................................................................................................................................................................................................................................................................................................................................................... 9163
1.7 Adapting sliding sunroof adjustment control unit -J245-................................................................................................................................................................................................................................................................................................................................................................................................... 9163
1.8 Checking and adjusting zero position for cables (slotted guide)........................................................................................................................................................................................................................................................................................................................................................................................... 9164
1.9 Adjusting zero position for sliding sunroof adjustment control unit -J245- (motor)........................................................................................................................................................................................................................................................................................................................................................................ 9164
2 Water drain hoses............................................................................................................................................................................................................................................................................................................................................................................................................................................... 9165
2.1 Overview - water drain hoses.............................................................................................................................................................................................................................................................................................................................................................................................................................. 9165
2.2 Cleaning water drain hoses................................................................................................................................................................................................................................................................................................................................................................................................................................ 9165
2.3 Removing and installing water drain hoses................................................................................................................................................................................................................................................................................................................................................................................................................. 9166
63 – Bumpers.......................................................................................................................................................................................................................................................................................................................................................................................................................................................... 9168
1 Bumper (front).................................................................................................................................................................................................................................................................................................................................................................................................................................................. 9168
1.1 Exploded view - bumper cover.............................................................................................................................................................................................................................................................................................................................................................................................................................. 9168
1.1.1 Exploded view - bumper cover, all vehicles except Audi S5........................................................................................................................................................................................................................................................................................................................................................................................... 9168
1.2 Exploded view - impact bar................................................................................................................................................................................................................................................................................................................................................................................................................................ 9171
1.3 Removing and installing lock carrier cover................................................................................................................................................................................................................................................................................................................................................................................................................ 9172
1.4 Removing and installing bumper cover...................................................................................................................................................................................................................................................................................................................................................................................................................... 9172
1.5 Gap widths at bumper cover................................................................................................................................................................................................................................................................................................................................................................................................................................ 9173
1.6 Adjusting bumper cover.................................................................................................................................................................................................................................................................................................................................................................................................................................... 9174
1.7 Removing and installing guides for bumper................................................................................................................................................................................................................................................................................................................................................................................................................. 9174
1.8 Removing and installing air intake grille................................................................................................................................................................................................................................................................................................................................................................................................................. 9174
1.9 Removing and installing attachments....................................................................................................................................................................................................................................................................................................................................................................................................................... 9175
1.10 Removing and installing impact absorber.................................................................................................................................................................................................................................................................................................................................................................................................................. 9176
1.11 Removing and installing impact bar....................................................................................................................................................................................................................................................................................................................................................................................................................... 9176
1.12 Removing and installing mounting for impact bar.......................................................................................................................................................................................................................................................................................................................................................................................................... 9177
2 Bumper (rear)................................................................................................................................................................................................................................................................................................................................................................................................................................................... 9178
2.1 Exploded view - bumper cover.............................................................................................................................................................................................................................................................................................................................................................................................................................. 9178
2.2 Exploded view - impact bar................................................................................................................................................................................................................................................................................................................................................................................................................................ 9180
2.3 Removing and installing bumper cover...................................................................................................................................................................................................................................................................................................................................................................................................................... 9181
2.4 Gap widths at bumper cover................................................................................................................................................................................................................................................................................................................................................................................................................................ 9182
2.5 Removing and installing guides for bumper................................................................................................................................................................................................................................................................................................................................................................................................................. 9183
2.6 Removing and installing attachments....................................................................................................................................................................................................................................................................................................................................................................................................................... 9184
2.7 Removing and installing impact bar........................................................................................................................................................................................................................................................................................................................................................................................................................ 9185
2.7.1 Removing and installing impact bar - vehicles without towing bracket................................................................................................................................................................................................................................................................................................................................................................................ 9185
2.7.2 Removing and installing impact bar - vehicles with towing bracket................................................................................................................................................................................................................................................................................................................................................................................... 9185
2.8 Removing and installing mounting for impact bar........................................................................................................................................................................................................................................................................................................................................................................................................... 9186
64 – Glazing.......................................................................................................................................................................................................................................................................................................................................................................................................................................................... 9188
1 Notes on repairs................................................................................................................................................................................................................................................................................................................................................................................................................................................ 9188
1.1 Minimum drying times for flush-bonded windows............................................................................................................................................................................................................................................................................................................................................................................................................. 9188
1.2 Repairing windows......................................................................................................................................................................................................................................................................................................................................................................................................................................... 9188
1.3 Notes on installing flush-bonded windows.................................................................................................................................................................................................................................................................................................................................................................................................................. 9189
1.4 Cleaning off adhesive sealant............................................................................................................................................................................................................................................................................................................................................................................................................................. 9192
1.5 Re-sealing windows........................................................................................................................................................................................................................................................................................................................................................................................................................................ 9192
2 Windscreen...................................................................................................................................................................................................................................................................................................................................................................................................................................................... 9193
2.1 Exploded view - windscreen................................................................................................................................................................................................................................................................................................................................................................................................................................ 9193
2.2 Removing and installing windscreen........................................................................................................................................................................................................................................................................................................................................................................................................................ 9194
3 Rear window..................................................................................................................................................................................................................................................................................................................................................................................................................................................... 9201
3.1 Exploded view - rear window............................................................................................................................................................................................................................................................................................................................................................................................................................... 9201
3.2 Removing and installing rear window....................................................................................................................................................................................................................................................................................................................................................................................................................... 9202
4 Side windows.................................................................................................................................................................................................................................................................................................................................................................................................................................................... 9210
4.1 Exploded view - side window............................................................................................................................................................................................................................................................................................................................................................................................................................... 9210
4.2 Removing and installing side window....................................................................................................................................................................................................................................................................................................................................................................................................................... 9210
5 Door windows.................................................................................................................................................................................................................................................................................................................................................................................................................................................... 9213
5.1 Exploded view - front door window......................................................................................................................................................................................................................................................................................................................................................................................................................... 9213
5.2 Exploded view - rear door window.......................................................................................................................................................................................................................................................................................................................................................................................................................... 9214
5.3 Removing and installing front door window................................................................................................................................................................................................................................................................................................................................................................................................................. 9215
5.4 Adjusting front door window............................................................................................................................................................................................................................................................................................................................................................................................................................... 9215
5.5 Removing and installing rear door window.................................................................................................................................................................................................................................................................................................................................................................................................................. 9220
5.6 Adjusting rear door window................................................................................................................................................................................................................................................................................................................................................................................................................................ 9220
66 – Exterior equipment............................................................................................................................................................................................................................................................................................................................................................................................................................................... 9226
1 Radiator grille/front trim panel................................................................................................................................................................................................................................................................................................................................................................................................................................ 9226
1.1 Exploded view - radiator grille........................................................................................................................................................................................................................................................................................................................................................................................................................... 9226
1.2 Removing and installing radiator grille................................................................................................................................................................................................................................................................................................................................................................................................................... 9227
1.3 Removing and installing bracket for ambient temperature sensor -G17-...................................................................................................................................................................................................................................................................................................................................................................................... 9228
2 Spoilers........................................................................................................................................................................................................................................................................................................................................................................................................................................................ 9229
2.1 Removing and installing spoiler........................................................................................................................................................................................................................................................................................................................................................................................................................... 9229
2.2 Removing and installing spoiler (bottom).................................................................................................................................................................................................................................................................................................................................................................................................................. 9230
3 Strips / trim panels / extensions............................................................................................................................................................................................................................................................................................................................................................................................................................... 9231
3.1 Exploded view - heat shield............................................................................................................................................................................................................................................................................................................................................................................................................................... 9231
3.2 Exploded view - trim panel for B-pillar................................................................................................................................................................................................................................................................................................................................................................................................................... 9233
3.3 Removing and installing trim strip........................................................................................................................................................................................................................................................................................................................................................................................................................ 9234
3.4 Removing and installing sill panel trim................................................................................................................................................................................................................................................................................................................................................................................................................... 9235
3.5 Removing and installing side member trim.................................................................................................................................................................................................................................................................................................................................................................................................................. 9236
3.6 Removing and installing water deflector strip............................................................................................................................................................................................................................................................................................................................................................................................................. 9237
4 Noise insulation................................................................................................................................................................................................................................................................................................................................................................................................................................................ 9238
4.1 Exploded view - noise insulation.......................................................................................................................................................................................................................................................................................................................................................................................................................... 9238
4.2 Removing and installing noise insulation.................................................................................................................................................................................................................................................................................................................................................................................................................. 9239
5 Underbody trim.................................................................................................................................................................................................................................................................................................................................................................................................................................................. 9240
5.1 Exploded view - underbody trim............................................................................................................................................................................................................................................................................................................................................................................................................................ 9240
5.2 Exploded view - tunnel cross-piece........................................................................................................................................................................................................................................................................................................................................................................................................................ 9242
6 Roof strips / roof rails........................................................................................................................................................................................................................................................................................................................................................................................................................................ 9243
6.1 Exploded view - roof trim strip........................................................................................................................................................................................................................................................................................................................................................................................................................... 9243
7 Exterior mirrors................................................................................................................................................................................................................................................................................................................................................................................................................................................ 9245
7.1 Exploded view - exterior mirror........................................................................................................................................................................................................................................................................................................................................................................................................................... 9245
7.2 Removing and installing exterior mirror................................................................................................................................................................................................................................................................................................................................................................................................................... 9246
7.3 Removing and installing mirror glass...................................................................................................................................................................................................................................................................................................................................................................................................................... 9246
7.4 Removing and installing mirror adjustment unit............................................................................................................................................................................................................................................................................................................................................................................................................ 9247
7.5 Removing and installing cover for mirror.................................................................................................................................................................................................................................................................................................................................................................................................................. 9248
7.6 Removing and installing mirror trim....................................................................................................................................................................................................................................................................................................................................................................................................................... 9249
8 Wheel housing liner............................................................................................................................................................................................................................................................................................................................................................................................................................................. 9250
8.1 Exploded view - wheel housing liner (front)............................................................................................................................................................................................................................................................................................................................................................................................................... 9250
8.2 Exploded view - wheel housing liner (rear)................................................................................................................................................................................................................................................................................................................................................................................................................ 9251
8.3 Exploded view - wheel spoiler (front)..................................................................................................................................................................................................................................................................................................................................................................................................................... 9253
8.4 Removing and installing wheel housing liner (front)....................................................................................................................................................................................................................................................................................................................................................................................................... 9253
9 Model badges and brand emblems.................................................................................................................................................................................................................................................................................................................................................................................................................................. 9255
9.1 Renewing model badges and brand emblems................................................................................................................................................................................................................................................................................................................................................................................................................... 9255
9.2 Dimensions for rear lid................................................................................................................................................................................................................................................................................................................................................................................................................................... 9255
9.3 Dimensions for wing panel................................................................................................................................................................................................................................................................................................................................................................................................................................. 9259
General_body_repairs__interior............................................................................................................................................................................................................................................................................................................................................................................................................................................ 9260
00 – Technical data................................................................................................................................................................................................................................................................................................................................................................................................................................................... 9270
1 Safety precautions.............................................................................................................................................................................................................................................................................................................................................................................................................................................. 9270
1.1 Safety precautions when working on pyrotechnic components................................................................................................................................................................................................................................................................................................................................................................................................. 9271
1.2 Safety precautions when working on vehicles with start/stop system........................................................................................................................................................................................................................................................................................................................................................................................ 9273
1.3 Storing, transporting and disposing of airbag units, belt tensioner units and battery isolation units (pyrotechnic components)............................................................................................................................................................................................................................................................................................................................ 9273
1.4 Additional safety regulations for side airbags............................................................................................................................................................................................................................................................................................................................................................................................................ 9274
1.5 Additional safety regulations for curtain airbags......................................................................................................................................................................................................................................................................................................................................................................................................... 9274
1.6 Safety regulations for crash sensors (pressure sensors) for side airbag (front)........................................................................................................................................................................................................................................................................................................................................................................... 9275
1.7 Additional safety regulations for working on seat occupied sensor controlling deactivation of front passenger airbag - country-specific version........................................................................................................................................................................................................................................................................................................... 9275
1.8 Procedure for dealing with seat occupied sensor controlling deactivation of front passenger airbag following an accident - country-specific version....................................................................................................................................................................................................................................................................................................... 9276
1.9 Renewing pyrotechnic, electrical and mechanical components of the restraint system following an accident.................................................................................................................................................................................................................................................................................................................................................. 9276
1.10 Checking airbag mounting components following an accident................................................................................................................................................................................................................................................................................................................................................................................................ 9278
1.11 Accident in which no airbag was triggered................................................................................................................................................................................................................................................................................................................................................................................................................ 9279
1.12 Checking seat belts...................................................................................................................................................................................................................................................................................................................................................................................................................................... 9279
1.13 Checking belt............................................................................................................................................................................................................................................................................................................................................................................................................................................ 9279
1.14 Checking automatic belt retractor (locking action)....................................................................................................................................................................................................................................................................................................................................................................................................... 9280
1.15 Visual inspection of belt buckle......................................................................................................................................................................................................................................................................................................................................................................................................................... 9281
1.16 Functional check of belt buckle.......................................................................................................................................................................................................................................................................................................................................................................................................................... 9281
1.17 Checking guide fittings and latch plate.................................................................................................................................................................................................................................................................................................................................................................................................................. 9281
1.18 Checking securing components and anchorage points following an accident.................................................................................................................................................................................................................................................................................................................................................................................. 9281
1.19 Checking child seat restraint function of seat belt for additional child seats (not for driver's seat belt; country-specific version).................................................................................................................................................................................................................................................................................................................... 9282
1.20 Checking child seat anchors following an accident........................................................................................................................................................................................................................................................................................................................................................................................................ 9282
1.21 Interior mirror.......................................................................................................................................................................................................................................................................................................................................................................................................................................... 9283
2 Notes on repairs................................................................................................................................................................................................................................................................................................................................................................................................................................................ 9284
2.1 Routing and attaching pipes and wiring.................................................................................................................................................................................................................................................................................................................................................................................................................... 9284
2.2 Contact corrosion......................................................................................................................................................................................................................................................................................................................................................................................................................................... 9284
68 – Interior equipment............................................................................................................................................................................................................................................................................................................................................................................................................................................... 9285
1 Shelves / trim panels........................................................................................................................................................................................................................................................................................................................................................................................................................................... 9285
1.1 Overview of fitting locations - shelves/covers/trim panels................................................................................................................................................................................................................................................................................................................................................................................................ 9285
1.2 Exploded view - dash panel cover (driver side)............................................................................................................................................................................................................................................................................................................................................................................................................ 9287
1.3 Exploded view - steering column trim...................................................................................................................................................................................................................................................................................................................................................................................................................... 9288
1.4 Exploded view - glove box................................................................................................................................................................................................................................................................................................................................................................................................................................. 9289
1.5 Removing and installing dash panel cover (driver side).................................................................................................................................................................................................................................................................................................................................................................................................... 9290
1.6 Removing and installing trim cover for dash panel insert.................................................................................................................................................................................................................................................................................................................................................................................................. 9291
1.7 Removing and installing dash panel cover (passenger side)................................................................................................................................................................................................................................................................................................................................................................................................. 9292
1.8 Removing and installing steering column trim (top)........................................................................................................................................................................................................................................................................................................................................................................................................ 9292
1.9 Removing and installing steering column trim (bottom)..................................................................................................................................................................................................................................................................................................................................................................................................... 9293
1.10 Removing and installing glove box opening mechanism...................................................................................................................................................................................................................................................................................................................................................................................................... 9293
1.11 Removing and installing glove box........................................................................................................................................................................................................................................................................................................................................................................................................................ 9294
1.12 Removing and installing glove box lid.................................................................................................................................................................................................................................................................................................................................................................................................................... 9296
1.13 Removing and installing cushioning element for glove box lid............................................................................................................................................................................................................................................................................................................................................................................................. 9296
2 Equipment....................................................................................................................................................................................................................................................................................................................................................................................................................................................... 9297
2.1 Exploded view - sun visors................................................................................................................................................................................................................................................................................................................................................................................................................................ 9297
2.2 Removing and installing sun visor......................................................................................................................................................................................................................................................................................................................................................................................................................... 9298
2.3 Removing and installing centre bracket for sun visor...................................................................................................................................................................................................................................................................................................................................................................................................... 9298
2.4 Removing and installing roof grab handle.................................................................................................................................................................................................................................................................................................................................................................................................................. 9299
3 Centre console.................................................................................................................................................................................................................................................................................................................................................................................................................................................. 9301
3.1 Exploded view - centre console............................................................................................................................................................................................................................................................................................................................................................................................................................ 9301
3.1.1 Exploded view - centre console without front centre armrest......................................................................................................................................................................................................................................................................................................................................................................................... 9301
3.1.2 Exploded view - centre console with front centre armrest............................................................................................................................................................................................................................................................................................................................................................................................ 9303
3.2 Removing and installing centre console trim (rear)........................................................................................................................................................................................................................................................................................................................................................................................................ 9305
3.3 Removing and installing centre console cover.............................................................................................................................................................................................................................................................................................................................................................................................................. 9306
3.4 Removing and installing ashtray (rear).................................................................................................................................................................................................................................................................................................................................................................................................................... 9306
3.5 Removing and installing ashtray (front)................................................................................................................................................................................................................................................................................................................................................................................................................... 9306
3.6 Removing and installing ashtray trim (front).............................................................................................................................................................................................................................................................................................................................................................................................................. 9307
3.7 Removing and installing insert for centre console......................................................................................................................................................................................................................................................................................................................................................................................................... 9307
3.8 Removing and installing centre console storage box (front)................................................................................................................................................................................................................................................................................................................................................................................................ 9308
3.9 Removing and installing air vent in centre console (rear)................................................................................................................................................................................................................................................................................................................................................................................................. 9308
3.10 Removing and installing centre console................................................................................................................................................................................................................................................................................................................................................................................................................... 9309
3.11 Removing and installing trim panel for centre console.................................................................................................................................................................................................................................................................................................................................................................................................... 9310
3.12 Removing and installing cup holder....................................................................................................................................................................................................................................................................................................................................................................................................................... 9311
3.13 Removing and installing centre console storage box (rear)................................................................................................................................................................................................................................................................................................................................................................................................ 9311
3.14 Removing and installing bracket for centre console....................................................................................................................................................................................................................................................................................................................................................................................................... 9313
4 Centre armrest (front).......................................................................................................................................................................................................................................................................................................................................................................................................................................... 9314
4.1 Exploded view - centre armrest (front).................................................................................................................................................................................................................................................................................................................................................................................................................... 9314
4.2 Removing and installing centre armrest (front)............................................................................................................................................................................................................................................................................................................................................................................................................ 9315
4.3 Removing and installing centre armrest (top section)...................................................................................................................................................................................................................................................................................................................................................................................................... 9315
4.4 Removing and installing trim for hinge arm................................................................................................................................................................................................................................................................................................................................................................................................................ 9316
5 Interior mirror................................................................................................................................................................................................................................................................................................................................................................................................................................................. 9317
5.1 Exploded view - interior mirror........................................................................................................................................................................................................................................................................................................................................................................................................................... 9317
5.2 Removing and installing interior mirror................................................................................................................................................................................................................................................................................................................................................................................................................... 9318
5.3 Switching automatic anti-dazzle function on and off....................................................................................................................................................................................................................................................................................................................................................................................................... 9319
5.4 Switching compass display on and off...................................................................................................................................................................................................................................................................................................................................................................................................................... 9320
5.5 Setting magnetic deflection zone.......................................................................................................................................................................................................................................................................................................................................................................................................................... 9320
5.6 Calibrating digital compass............................................................................................................................................................................................................................................................................................................................................................................................................................... 9320
5.7 Adjusting automatic anti-dazzle interior mirror for right-hand drive or left-hand drive vehicles.......................................................................................................................................................................................................................................................................................................................................................... 9321
5.8 Selecting the applicable deflection zone from the map..................................................................................................................................................................................................................................................................................................................................................................................................... 9321
5.9 Checking operation of automatic anti-dazzle interior mirror............................................................................................................................................................................................................................................................................................................................................................................................... 9327
69 – Passenger protection............................................................................................................................................................................................................................................................................................................................................................................................................................................. 9329
1 Seat belts...................................................................................................................................................................................................................................................................................................................................................................................................................................................... 9329
1.1 Overview of fitting locations - seat belts and anchorage points........................................................................................................................................................................................................................................................................................................................................................................................... 9329
1.2 Exploded view - three-point seat belt (front)............................................................................................................................................................................................................................................................................................................................................................................................................. 9331
1.3 Exploded view - outer three-point seat belt (rear)........................................................................................................................................................................................................................................................................................................................................................................................................ 9332
1.4 Exploded view - belt buckle (front)....................................................................................................................................................................................................................................................................................................................................................................................................................... 9333
1.5 Exploded view - belt buckle (rear)........................................................................................................................................................................................................................................................................................................................................................................................................................ 9334
1.6 Removing and installing three-point seat belt (front)..................................................................................................................................................................................................................................................................................................................................................................................................... 9334
1.7 Removing and installing three-point seat belt (rear)...................................................................................................................................................................................................................................................................................................................................................................................................... 9336
1.8 Removing and installing belt guide (front)................................................................................................................................................................................................................................................................................................................................................................................................................ 9338
1.9 Removing and installing belt guide (rear)................................................................................................................................................................................................................................................................................................................................................................................................................. 9339
1.10 Removing and installing belt end fitting (front)......................................................................................................................................................................................................................................................................................................................................................................................................... 9340
1.11 Removing and installing outer belt end fitting (rear).................................................................................................................................................................................................................................................................................................................................................................................................... 9340
1.12 Removing and installing belt height adjuster............................................................................................................................................................................................................................................................................................................................................................................................................. 9341
1.13 Removing and installing belt buckle (front).............................................................................................................................................................................................................................................................................................................................................................................................................. 9342
1.14 Removing and installing belt buckle (rear)............................................................................................................................................................................................................................................................................................................................................................................................................... 9343
2 Child seat anchors.............................................................................................................................................................................................................................................................................................................................................................................................................................................. 9345
2.1 Exploded view - child seat anchors (front)................................................................................................................................................................................................................................................................................................................................................................................................................ 9345
2.2 Exploded view - child seat anchors (rear)................................................................................................................................................................................................................................................................................................................................................................................................................. 9346
2.3 Removing and installing child seat anchor (front)......................................................................................................................................................................................................................................................................................................................................................................................................... 9347
2.4 Removing and installing child seat anchor (rear).......................................................................................................................................................................................................................................................................................................................................................................................................... 9347
3 Airbag system................................................................................................................................................................................................................................................................................................................................................................................................................................................... 9349
3.1 Overview of fitting locations - airbag system............................................................................................................................................................................................................................................................................................................................................................................................................. 9349
4 Airbag control unit............................................................................................................................................................................................................................................................................................................................................................................................................................................. 9351
4.1 Exploded view - airbag control unit....................................................................................................................................................................................................................................................................................................................................................................................................................... 9351
4.2 Removing and installing airbag control unit -J234-........................................................................................................................................................................................................................................................................................................................................................................................................ 9351
5 Battery isolation igniter....................................................................................................................................................................................................................................................................................................................................................................................................................................... 9355
5.1 Exploded view - battery isolation igniter................................................................................................................................................................................................................................................................................................................................................................................................................. 9355
5.2 Removing and installing battery isolation igniter......................................................................................................................................................................................................................................................................................................................................................................................................... 9355
6 Airbag (driver side)............................................................................................................................................................................................................................................................................................................................................................................................................................................ 9359
6.1 Exploded view - airbag (driver side)...................................................................................................................................................................................................................................................................................................................................................................................................................... 9359
6.1.1 Exploded view - airbag, bolted version (driver side)................................................................................................................................................................................................................................................................................................................................................................................................ 9359
6.1.2 Exploded view - airbag, push-fitted version (driver side)........................................................................................................................................................................................................................................................................................................................................................................................... 9360
6.2 Removing and installing airbag unit with igniters......................................................................................................................................................................................................................................................................................................................................................................................................... 9361
6.2.1 Removing and installing airbag unit with igniters - bolted airbag version........................................................................................................................................................................................................................................................................................................................................................................... 9361
6.2.2 Removing and installing airbag unit with igniters - push-fitted airbag version...................................................................................................................................................................................................................................................................................................................................................................... 9364
6.3 Renewing connector at airbag.............................................................................................................................................................................................................................................................................................................................................................................................................................. 9368
6.3.1 Renewing connector at airbag (bolted version)....................................................................................................................................................................................................................................................................................................................................................................................................... 9368
6.3.2 Renewing connector at airbag (push-fitted version).................................................................................................................................................................................................................................................................................................................................................................................................. 9369
7 Airbag (front passenger side)................................................................................................................................................................................................................................................................................................................................................................................................................................... 9371
7.1 Exploded view - airbag (front passenger side)............................................................................................................................................................................................................................................................................................................................................................................................................. 9371
7.2 Removing and installing airbag unit (front passenger side) with igniters.................................................................................................................................................................................................................................................................................................................................................................................. 9372
7.3 Removing and installing key operated switch to deactivate front passenger side airbag..................................................................................................................................................................................................................................................................................................................................................................... 9374
8 Side airbags.................................................................................................................................................................................................................................................................................................................................................................................................................................................... 9376
8.1 Exploded view - side airbag (front)....................................................................................................................................................................................................................................................................................................................................................................................................................... 9376
8.2 Exploded view - side airbag (rear)........................................................................................................................................................................................................................................................................................................................................................................................................................ 9377
8.3 Removing and installing side airbag (front) with airbag igniter........................................................................................................................................................................................................................................................................................................................................................................................... 9377
8.4 Removing and installing side airbag (rear) with airbag igniter............................................................................................................................................................................................................................................................................................................................................................................................ 9379
8.5 Deactivating side airbag (rear)........................................................................................................................................................................................................................................................................................................................................................................................................................... 9381
8.6 Activating side airbag (rear)............................................................................................................................................................................................................................................................................................................................................................................................................................. 9383
8.7 Sticker for deactivated side airbag (rear)................................................................................................................................................................................................................................................................................................................................................................................................................ 9385
9 Curtain airbags................................................................................................................................................................................................................................................................................................................................................................................................................................................. 9386
9.1 Exploded view - curtain airbag............................................................................................................................................................................................................................................................................................................................................................................................................................ 9386
9.2 Removing and installing curtain airbag with airbag igniter................................................................................................................................................................................................................................................................................................................................................................................................ 9387
10 Crash sensors for airbags...................................................................................................................................................................................................................................................................................................................................................................................................................................... 9391
10.1 Overview of fitting locations - crash sensors for airbags................................................................................................................................................................................................................................................................................................................................................................................................ 9391
10.2 Removing and installing front airbag crash sensor for driver side -G283-................................................................................................................................................................................................................................................................................................................................................................................. 9392
10.3 Removing and installing crash sensor for side airbag (front) -G179-/-G180-............................................................................................................................................................................................................................................................................................................................................................................... 9394
10.4 Removing and installing crash sensor for side airbag (rear) -G256-/-G257-................................................................................................................................................................................................................................................................................................................................................................................ 9396
11 Seat position sensor........................................................................................................................................................................................................................................................................................................................................................................................................................................... 9398
11.1 Exploded view - seat position sensor..................................................................................................................................................................................................................................................................................................................................................................................................................... 9398
11.2 Removing and installing seat position sensor............................................................................................................................................................................................................................................................................................................................................................................................................. 9398
12 Belt-fastened recognition system............................................................................................................................................................................................................................................................................................................................................................................................................................... 9403
12.1 Removing and installing seat occupied sensor (front passenger side) -G128-............................................................................................................................................................................................................................................................................................................................................................................... 9403
70 – Trim, insulation................................................................................................................................................................................................................................................................................................................................................................................................................................................. 9408
1 Door trim (front)............................................................................................................................................................................................................................................................................................................................................................................................................................................... 9408
1.1 Exploded view - door trim (front)......................................................................................................................................................................................................................................................................................................................................................................................................................... 9408
1.2 Removing and installing mid-range loudspeaker trim........................................................................................................................................................................................................................................................................................................................................................................................................ 9411
1.3 Removing and installing treble loudspeaker trim........................................................................................................................................................................................................................................................................................................................................................................................................... 9412
1.4 Removing and installing bracket for treble loudspeaker.................................................................................................................................................................................................................................................................................................................................................................................................... 9412
1.5 Removing and installing trim for armrest (front).......................................................................................................................................................................................................................................................................................................................................................................................................... 9413
1.6 Removing and installing trim panel........................................................................................................................................................................................................................................................................................................................................................................................................................ 9414
1.7 Removing and installing door trim (front)................................................................................................................................................................................................................................................................................................................................................................................................................. 9414
1.8 Removing and installing armrest (front)................................................................................................................................................................................................................................................................................................................................................................................................................... 9417
1.9 Removing and installing door puller (front)............................................................................................................................................................................................................................................................................................................................................................................................................... 9417
1.10 Removing and installing interior door handle............................................................................................................................................................................................................................................................................................................................................................................................................. 9418
1.11 Removing and installing switch trim for driver seat memory operating unit -E97-.......................................................................................................................................................................................................................................................................................................................................................................... 9418
2 Door trim (rear)................................................................................................................................................................................................................................................................................................................................................................................................................................................ 9419
2.1 Exploded view - door trim (rear).......................................................................................................................................................................................................................................................................................................................................................................................................................... 9419
2.2 Removing and installing treble loudspeaker trim........................................................................................................................................................................................................................................................................................................................................................................................................... 9421
2.3 Removing and installing trim for armrest (rear)........................................................................................................................................................................................................................................................................................................................................................................................................... 9421
2.4 Removing and installing door trim (rear).................................................................................................................................................................................................................................................................................................................................................................................................................. 9422
2.5 Removing and installing armrest (rear).................................................................................................................................................................................................................................................................................................................................................................................................................... 9423
2.6 Removing and installing door puller (rear)................................................................................................................................................................................................................................................................................................................................................................................................................ 9424
3 Dash panel...................................................................................................................................................................................................................................................................................................................................................................................................................................................... 9425
3.1 Overview of fitting locations - dash panel................................................................................................................................................................................................................................................................................................................................................................................................................ 9425
3.2 Exploded view - dash panel................................................................................................................................................................................................................................................................................................................................................................................................................................ 9427
3.3 Removing and installing dash panel cover (side)........................................................................................................................................................................................................................................................................................................................................................................................................... 9430
3.4 Removing and installing cover for MMI screen.............................................................................................................................................................................................................................................................................................................................................................................................................. 9430
3.5 Removing and installing loudspeaker trim.................................................................................................................................................................................................................................................................................................................................................................................................................. 9431
3.5.1 Removing and installing loudspeaker trim (side)..................................................................................................................................................................................................................................................................................................................................................................................................... 9431
3.5.2 Removing and installing loudspeaker trim (centre)................................................................................................................................................................................................................................................................................................................................................................................................... 9432
3.6 Removing and installing trim for light switch............................................................................................................................................................................................................................................................................................................................................................................................................. 9433
3.7 Removing and installing mounting frame for radio/navigation system........................................................................................................................................................................................................................................................................................................................................................................................ 9433
3.8 Removing and installing trim for entry and start authorisation switch..................................................................................................................................................................................................................................................................................................................................................................................... 9433
3.9 Removing and installing retaining frame for dash panel insert............................................................................................................................................................................................................................................................................................................................................................................................. 9434
3.10 Removing and installing dash panel....................................................................................................................................................................................................................................................................................................................................................................................................................... 9434
3.11 Removing and installing loudspeaker mounting............................................................................................................................................................................................................................................................................................................................................................................................................. 9439
3.12 Removing and installing dash panel vent.................................................................................................................................................................................................................................................................................................................................................................................................................. 9439
3.12.1 Removing and installing dash panel vent (side)..................................................................................................................................................................................................................................................................................................................................................................................................... 9439
3.12.2 Removing and installing dash panel vent (centre)................................................................................................................................................................................................................................................................................................................................................................................................... 9440
3.13 Removing and installing defroster vent (front centre).................................................................................................................................................................................................................................................................................................................................................................................................... 9441
4 Central tube for dash panel..................................................................................................................................................................................................................................................................................................................................................................................................................................... 9442
4.1 Exploded view - central tube for dash panel............................................................................................................................................................................................................................................................................................................................................................................................................... 9442
4.2 Removing and installing central tube for dash panel....................................................................................................................................................................................................................................................................................................................................................................................................... 9443
4.3 Removing and installing mounting bracket.................................................................................................................................................................................................................................................................................................................................................................................................................. 9447
4.4 Removing and installing glove box bracket(s).............................................................................................................................................................................................................................................................................................................................................................................................................. 9447
5 Passenger compartment trim panels............................................................................................................................................................................................................................................................................................................................................................................................................................... 9448
5.1 Overview of fitting locations - passenger compartment trim panels......................................................................................................................................................................................................................................................................................................................................................................................... 9448
5.2 Exploded view - sill panel trim........................................................................................................................................................................................................................................................................................................................................................................................................................... 9450
5.2.1 Exploded view - sill panel trim (front)............................................................................................................................................................................................................................................................................................................................................................................................................. 9450
5.2.2 Exploded view - sill panel trim (rear).............................................................................................................................................................................................................................................................................................................................................................................................................. 9451
5.3 Exploded view - A-pillar trim............................................................................................................................................................................................................................................................................................................................................................................................................................. 9452
5.4 Exploded view - B-pillar trim............................................................................................................................................................................................................................................................................................................................................................................................................................. 9453
5.5 Exploded view - C-pillar trim............................................................................................................................................................................................................................................................................................................................................................................................................................. 9454
5.6 Exploded view - D-pillar trim............................................................................................................................................................................................................................................................................................................................................................................................................................. 9455
5.7 Exploded view - foot rest and floor covering.............................................................................................................................................................................................................................................................................................................................................................................................................. 9456
5.8 Exploded view - rear shelf................................................................................................................................................................................................................................................................................................................................................................................................................................ 9457
5.9 Removing and installing sill panel trim................................................................................................................................................................................................................................................................................................................................................................................................................... 9457
5.9.1 Removing and installing sill panel trim (front)..................................................................................................................................................................................................................................................................................................................................................................................................... 9457
5.9.2 Removing and installing sill panel trim (rear)...................................................................................................................................................................................................................................................................................................................................................................................................... 9459
5.10 Removing and installing A-pillar trim.................................................................................................................................................................................................................................................................................................................................................................................................................... 9459
5.11 Removing and installing trim cover for A-pillar trim..................................................................................................................................................................................................................................................................................................................................................................................................... 9461
5.12 Removing and installing B-pillar trim.................................................................................................................................................................................................................................................................................................................................................................................................................... 9461
5.12.1 Removing and installing B-pillar trim (top)........................................................................................................................................................................................................................................................................................................................................................................................................ 9461
5.12.2 Removing and installing B-pillar trim (bottom)..................................................................................................................................................................................................................................................................................................................................................................................................... 9463
5.13 Removing and installing C-pillar trim.................................................................................................................................................................................................................................................................................................................................................................................................................... 9463
5.14 Removing and installing D-pillar trim.................................................................................................................................................................................................................................................................................................................................................................................................................... 9465
5.15 Removing and installing foot rest........................................................................................................................................................................................................................................................................................................................................................................................................................ 9466
5.16 Removing and installing floor covering................................................................................................................................................................................................................................................................................................................................................................................................................... 9467
5.17 Removing and installing rear shelf....................................................................................................................................................................................................................................................................................................................................................................................................................... 9468
5.17.1 Removing and installing front section of rear shelf................................................................................................................................................................................................................................................................................................................................................................................................ 9468
5.17.2 Removing and installing rear section of rear shelf................................................................................................................................................................................................................................................................................................................................................................................................. 9468
6 Luggage compartment trim panels................................................................................................................................................................................................................................................................................................................................................................................................................................. 9469
6.1 Overview of fitting locations - luggage compartment trim panels........................................................................................................................................................................................................................................................................................................................................................................................... 9469
6.2 Exploded view - luggage compartment side trim............................................................................................................................................................................................................................................................................................................................................................................................................. 9472
6.3 Exploded view - luggage compartment floor................................................................................................................................................................................................................................................................................................................................................................................................................. 9473
6.4 Exploded view - rear lid trim (bottom).................................................................................................................................................................................................................................................................................................................................................................................................................... 9474
6.5 Exploded view - rear lid trim (top)....................................................................................................................................................................................................................................................................................................................................................................................................................... 9475
6.6 Exploded view - lock carrier trim......................................................................................................................................................................................................................................................................................................................................................................................................................... 9476
6.7 Removing and installing rear lid trim (bottom)............................................................................................................................................................................................................................................................................................................................................................................................................ 9476
6.8 Removing and installing rear lid trim (top)............................................................................................................................................................................................................................................................................................................................................................................................................... 9477
6.9 Removing and installing lock carrier trim................................................................................................................................................................................................................................................................................................................................................................................................................. 9478
6.10 Removing and installing fastening ring................................................................................................................................................................................................................................................................................................................................................................................................................... 9479
6.11 Removing and installing bracket for fastening ring....................................................................................................................................................................................................................................................................................................................................................................................................... 9479
6.12 Removing and installing bag hook......................................................................................................................................................................................................................................................................................................................................................................................................................... 9480
6.13 Removing and installing luggage compartment side trim.................................................................................................................................................................................................................................................................................................................................................................................................... 9480
6.14 Removing and installing luggage compartment floor........................................................................................................................................................................................................................................................................................................................................................................................................ 9482
6.15 Removing and installing retainer for luggage compartment floor........................................................................................................................................................................................................................................................................................................................................................................................... 9482
6.16 Removing and installing mounting frame for loading aid................................................................................................................................................................................................................................................................................................................................................................................................... 9483
6.17 Removing and installing lining for spare wheel well...................................................................................................................................................................................................................................................................................................................................................................................................... 9483
6.18 Removing and installing tail light cover................................................................................................................................................................................................................................................................................................................................................................................................................. 9484
6.19 Removing and installing trim for rear lid lock........................................................................................................................................................................................................................................................................................................................................................................................................... 9484
7 Roof trim panels................................................................................................................................................................................................................................................................................................................................................................................................................................................ 9485
7.1 Overview of fitting locations - roof trim................................................................................................................................................................................................................................................................................................................................................................................................................. 9485
7.2 Exploded view - moulded headliner......................................................................................................................................................................................................................................................................................................................................................................................................................... 9486
7.3 Removing and installing moulded headliner................................................................................................................................................................................................................................................................................................................................................................................................................. 9486
7.4 Attaching roof reinforcement to body...................................................................................................................................................................................................................................................................................................................................................................................................................... 9489
7.4.1 Attaching roof reinforcement to body - equipment version without sliding sunroof.................................................................................................................................................................................................................................................................................................................................................................... 9489
7.4.2 Attaching roof reinforcement to body - equipment version with sliding sunroof....................................................................................................................................................................................................................................................................................................................................................................... 9490
72 – Seat frames...................................................................................................................................................................................................................................................................................................................................................................................................................................................... 9492
1 Overview - seat versions........................................................................................................................................................................................................................................................................................................................................................................................................................................ 9492
1.1 Overview of fitting locations - seat versions............................................................................................................................................................................................................................................................................................................................................................................................................. 9492
1.2 Attaching front seat to seat repair stand................................................................................................................................................................................................................................................................................................................................................................................................................. 9494
2 Front seats..................................................................................................................................................................................................................................................................................................................................................................................................................................................... 9497
2.1 Overview of fitting locations - electrical and electronic components...................................................................................................................................................................................................................................................................................................................................................................................... 9499
2.2 Exploded view - front seat................................................................................................................................................................................................................................................................................................................................................................................................................................ 9504
2.2.1 Exploded view - front standard seat with manual adjustment.......................................................................................................................................................................................................................................................................................................................................................................................... 9504
2.2.2 Exploded view - front standard seat with electric adjustment, front convenience seat................................................................................................................................................................................................................................................................................................................................................................ 9506
2.2.3 Exploded view - front sports seat with manual adjustment and seat depth adjustment.................................................................................................................................................................................................................................................................................................................................................................. 9508
2.2.4 Exploded view - front sports seat with electric adjustment.......................................................................................................................................................................................................................................................................................................................................................................................... 9510
2.2.5 Exploded view - front super sports seat............................................................................................................................................................................................................................................................................................................................................................................................................. 9512
2.3 Exploded view - modular wire routing...................................................................................................................................................................................................................................................................................................................................................................................................................... 9514
2.4 Exploded view - trim (sill side and tunnel side).......................................................................................................................................................................................................................................................................................................................................................................................................... 9515
2.4.1 Exploded view - trim (sill side and tunnel side), standard/sports seat with manual adjustment....................................................................................................................................................................................................................................................................................................................................................... 9515
2.4.2 Exploded view - trim (sill side and tunnel side), standard/sports seat with electric adjustment, convenience seat, super sports seat................................................................................................................................................................................................................................................................................................................ 9516
2.5 Exploded view - retaining bracket for trim (sill side).................................................................................................................................................................................................................................................................................................................................................................................................... 9517
2.5.1 Exploded view - retaining bracket for trim (sill side), standard/sports seat with manual adjustment................................................................................................................................................................................................................................................................................................................................................. 9517
2.5.2 Exploded view - retaining bracket for trim (sill side), standard/sports seat with electric adjustment, convenience seat, super sports seat.......................................................................................................................................................................................................................................................................................................... 9518
2.6 Exploded view - seat height adjustment unit and seat height adjuster...................................................................................................................................................................................................................................................................................................................................................................................... 9519
2.7 Exploded view - actuators for seat, backrest and head restraint adjustment................................................................................................................................................................................................................................................................................................................................................................................ 9520
2.8 Exploded view - torsion bar............................................................................................................................................................................................................................................................................................................................................................................................................................... 9521
2.9 Exploded view - backrest cover panel...................................................................................................................................................................................................................................................................................................................................................................................................................... 9522
2.9.1 Exploded view - two-piece backrest cover panel...................................................................................................................................................................................................................................................................................................................................................................................................... 9522
2.9.2 Exploded view - one-piece backrest cover panel...................................................................................................................................................................................................................................................................................................................................................................................................... 9523
2.10 Exploded view - front seat backrest...................................................................................................................................................................................................................................................................................................................................................................................................................... 9525
2.11 Exploded view - head restraint........................................................................................................................................................................................................................................................................................................................................................................................................................... 9526
2.11.1 Exploded view - head restraint, standard/sports seat with manual adjustment........................................................................................................................................................................................................................................................................................................................................................................ 9526
2.11.2 Exploded view - head restraint, standard/sports seat with electric adjustment, convenience seat.................................................................................................................................................................................................................................................................................................................................................... 9528
2.11.3 Exploded view - head restraint, super sports seat.................................................................................................................................................................................................................................................................................................................................................................................................. 9529
2.12 Exploded view - seat pan................................................................................................................................................................................................................................................................................................................................................................................................................................. 9530
2.13 Exploded view - spring mat............................................................................................................................................................................................................................................................................................................................................................................................................................... 9531
2.14 Exploded view - seat longitudinal adjuster............................................................................................................................................................................................................................................................................................................................................................................................................... 9532
2.15 Exploded view - seat rake adjuster....................................................................................................................................................................................................................................................................................................................................................................................................................... 9533
2.16 Exploded view - seat depth adjuster...................................................................................................................................................................................................................................................................................................................................................................................................................... 9534
2.17 Exploded view - storage compartment...................................................................................................................................................................................................................................................................................................................................................................................................................... 9535
2.18 Exploded view - lumbar support........................................................................................................................................................................................................................................................................................................................................................................................................................... 9536
2.18.1 Exploded view - lumbar support, all seats except convenience seat.................................................................................................................................................................................................................................................................................................................................................................................. 9536
2.18.2 Exploded view - lumbar support, convenience seat................................................................................................................................................................................................................................................................................................................................................................................................... 9537
2.19 Exploded view - seat and steering column adjustment control unit with memory function.................................................................................................................................................................................................................................................................................................................................................................... 9538
2.20 Exploded view - control unit for seat ventilation and seat heating....................................................................................................................................................................................................................................................................................................................................................................................... 9539
2.21 Exploded view - seat longitudinal adjustment motor....................................................................................................................................................................................................................................................................................................................................................................................................... 9540
2.22 Exploded view - backrest adjustment motor................................................................................................................................................................................................................................................................................................................................................................................................................ 9541
2.23 Exploded view - seat height adjustment motor............................................................................................................................................................................................................................................................................................................................................................................................................. 9542
2.24 Exploded view - seat rake adjustment motor............................................................................................................................................................................................................................................................................................................................................................................................................... 9543
2.25 Overview - seat cushion and backrest fans................................................................................................................................................................................................................................................................................................................................................................................................................ 9544
2.26 Removing and installing front seat....................................................................................................................................................................................................................................................................................................................................................................................................................... 9545
2.26.1 Removing and installing front standard/sports seat with manual adjustment.......................................................................................................................................................................................................................................................................................................................................................................... 9545
2.26.2 Removing and installing front standard/sports seat with electric adjustment, front convenience seat, front super sports seat....................................................................................................................................................................................................................................................................................................................... 9547
2.26.3 Removing and installing front seat (if seat longitudinal adjustment motor or control unit are defective)........................................................................................................................................................................................................................................................................................................................................... 9549
2.27 Unplugging and plugging in connectors.................................................................................................................................................................................................................................................................................................................................................................................................................... 9554
2.28 Connecting and disconnecting airbag adapter.............................................................................................................................................................................................................................................................................................................................................................................................................. 9556
2.29 Connector point connectors............................................................................................................................................................................................................................................................................................................................................................................................................................... 9559
2.30 Modular wire routing with corrugated tube on front seat.................................................................................................................................................................................................................................................................................................................................................................................................. 9559
2.31 Removing and installing backrest adjustment unit......................................................................................................................................................................................................................................................................................................................................................................................................... 9561
2.32 Removing and installing front seat backrest.............................................................................................................................................................................................................................................................................................................................................................................................................. 9562
2.33 Removing and installing head restraint................................................................................................................................................................................................................................................................................................................................................................................................................... 9565
2.33.1 Removing and installing head restraint - standard/sports seat with manual adjustment............................................................................................................................................................................................................................................................................................................................................................... 9565
2.33.2 Removing and installing head restraint - standard/sports seat with electric adjustment, convenience seat........................................................................................................................................................................................................................................................................................................................................... 9565
2.33.3 Removing and installing head restraint - super sports seat......................................................................................................................................................................................................................................................................................................................................................................................... 9567
2.34 Removing and installing head restraint guide............................................................................................................................................................................................................................................................................................................................................................................................................. 9567
2.34.1 Removing and installing head restraint guide - all seats except super sports seat.................................................................................................................................................................................................................................................................................................................................................................. 9567
2.34.2 Removing and installing head restraint guide - super sports seat................................................................................................................................................................................................................................................................................................................................................................................... 9569
2.35 Dismantling and assembling seat pan...................................................................................................................................................................................................................................................................................................................................................................................................................... 9571
2.36 Removing and installing actuator for backrest and head restraint adjustment.............................................................................................................................................................................................................................................................................................................................................................................. 9574
2.37 Removing and installing backrest cover panel............................................................................................................................................................................................................................................................................................................................................................................................................. 9575
2.37.1 Removing and installing two-piece backrest cover panel............................................................................................................................................................................................................................................................................................................................................................................................. 9575
2.37.2 Removing and installing one-piece backrest cover panel............................................................................................................................................................................................................................................................................................................................................................................................. 9578
2.38 Removing and installing trim for outer backrest frame.................................................................................................................................................................................................................................................................................................................................................................................................... 9580
2.39 Removing and installing spring mat....................................................................................................................................................................................................................................................................................................................................................................................................................... 9581
2.40 Removing and installing seat height adjuster............................................................................................................................................................................................................................................................................................................................................................................................................. 9583
2.41 Removing and installing seat height adjustment unit...................................................................................................................................................................................................................................................................................................................................................................................................... 9584
2.42 Removing and installing seat longitudinal adjustment handle.............................................................................................................................................................................................................................................................................................................................................................................................. 9586
2.43 Removing and installing Bowden cable for seat longitudinal adjustment.................................................................................................................................................................................................................................................................................................................................................................................... 9587
2.44 Removing and installing lever for engaging Bowden cable and spring for seat longitudinal adjustment...................................................................................................................................................................................................................................................................................................................................................... 9589
2.45 Repairing seat longitudinal adjuster, renewing connecting rod............................................................................................................................................................................................................................................................................................................................................................................................ 9591
2.46 Removing and installing seat adjustment actuator......................................................................................................................................................................................................................................................................................................................................................................................................... 9595
2.47 Removing and installing seat rake adjustment handle...................................................................................................................................................................................................................................................................................................................................................................................................... 9595
2.48 Removing and installing seat rake adjuster............................................................................................................................................................................................................................................................................................................................................................................................................... 9596
2.49 Removing and installing seat depth adjuster.............................................................................................................................................................................................................................................................................................................................................................................................................. 9597
2.50 Removing and installing trim for seat depth adjuster..................................................................................................................................................................................................................................................................................................................................................................................................... 9601
2.51 Removing and installing cover for seat rail.............................................................................................................................................................................................................................................................................................................................................................................................................. 9603
2.52 Removing and installing spindle cover (seat rail)........................................................................................................................................................................................................................................................................................................................................................................................................ 9605
2.53 Removing and installing trim (sill side)................................................................................................................................................................................................................................................................................................................................................................................................................. 9606
2.53.1 Removing and installing trim (sill side) - standard/sports seat with manual adjustment............................................................................................................................................................................................................................................................................................................................................................. 9606
2.53.2 Removing and installing trim (sill side) - standard/sports seat with electric adjustment, convenience seat, super sports seat...................................................................................................................................................................................................................................................................................................................... 9608
2.54 Removing and installing trim (tunnel side)............................................................................................................................................................................................................................................................................................................................................................................................................... 9610
2.55 Removing and installing retaining bracket for trim (sill side)........................................................................................................................................................................................................................................................................................................................................................................................... 9611
2.55.1 Removing and installing retaining bracket for trim (sill side) - standard/sports seat with manual adjustment....................................................................................................................................................................................................................................................................................................................................... 9611
2.55.2 Removing and installing retaining bracket for trim (sill side) - standard/sports seat with electric adjustment, convenience seat, super sports seat................................................................................................................................................................................................................................................................................................ 9612
2.56 Removing and installing torsion bar...................................................................................................................................................................................................................................................................................................................................................................................................................... 9612
2.57 Removing and installing bearing for torsion bar.......................................................................................................................................................................................................................................................................................................................................................................................................... 9616
2.58 Riveting pop rivet nut for retaining plate for DVD player to outer backrest frame........................................................................................................................................................................................................................................................................................................................................................................ 9618
2.59 Removing and installing retaining plate for DVD player................................................................................................................................................................................................................................................................................................................................................................................................... 9619
2.60 Removing and installing storage compartment.............................................................................................................................................................................................................................................................................................................................................................................................................. 9620
2.61 Removing and installing seat and steering column adjustment control unit with memory function............................................................................................................................................................................................................................................................................................................................................................ 9622
2.62 Removing and installing retainer for seat and steering column adjustment control unit with memory function............................................................................................................................................................................................................................................................................................................................................... 9624
2.63 Removing and installing control unit for seat ventilation and seat heating............................................................................................................................................................................................................................................................................................................................................................................... 9625
2.64 Removing and installing seat longitudinal adjustment motor............................................................................................................................................................................................................................................................................................................................................................................................... 9627
2.65 Removing and installing backrest adjustment motor........................................................................................................................................................................................................................................................................................................................................................................................................ 9627
2.66 Removing and installing seat height adjustment motor..................................................................................................................................................................................................................................................................................................................................................................................................... 9631
2.67 Removing and installing seat rake adjustment motor....................................................................................................................................................................................................................................................................................................................................................................................................... 9636
2.68 Removing and installing seat adjustment operating unit................................................................................................................................................................................................................................................................................................................................................................................................... 9638
2.69 Removing and installing lumbar support................................................................................................................................................................................................................................................................................................................................................................................................................... 9638
2.69.1 Removing and installing lumbar support - all seats except convenience seat......................................................................................................................................................................................................................................................................................................................................................................... 9638
2.69.2 Removing and installing lumbar support - convenience seat.......................................................................................................................................................................................................................................................................................................................................................................................... 9642
2.70 Removing and installing lumbar support adjustment motor -V125-/-V126-/-V129-/-V130-...................................................................................................................................................................................................................................................................................................................................................................... 9645
2.71 Removing and installing lumbar support adjustment switch -E176-/-E177-................................................................................................................................................................................................................................................................................................................................................................................... 9646
2.72 Removing and installing seat cushion fan................................................................................................................................................................................................................................................................................................................................................................................................................. 9647
2.73 Removing and installing backrest fan (top)............................................................................................................................................................................................................................................................................................................................................................................................................... 9648
2.74 Removing and installing backrest fan (bottom)............................................................................................................................................................................................................................................................................................................................................................................................................ 9648
3 Rear seats...................................................................................................................................................................................................................................................................................................................................................................................................................................................... 9650
3.1 Exploded view - seat bench/individual seats............................................................................................................................................................................................................................................................................................................................................................................................................... 9650
3.2 Exploded view - locking mechanism......................................................................................................................................................................................................................................................................................................................................................................................................................... 9652
3.3 Exploded view - head restraint and head restraint guide................................................................................................................................................................................................................................................................................................................................................................................................... 9653
3.4 Exploded view - rear seat backrest........................................................................................................................................................................................................................................................................................................................................................................................................................ 9654
3.5 Exploded view - centre armrest............................................................................................................................................................................................................................................................................................................................................................................................................................ 9656
3.5.1 Exploded view - centre armrest with load-through hatch.............................................................................................................................................................................................................................................................................................................................................................................................. 9656
3.5.2 Exploded view - centre armrest with storage compartment............................................................................................................................................................................................................................................................................................................................................................................................. 9657
3.5.3 Exploded view - centre armrest without storage compartment.......................................................................................................................................................................................................................................................................................................................................................................................... 9658
3.6 Removing and installing seat bench/individual seats....................................................................................................................................................................................................................................................................................................................................................................................................... 9659
3.7 Removing and installing head restraint.................................................................................................................................................................................................................................................................................................................................................................................................................... 9661
3.8 Removing and installing head restraint guide.............................................................................................................................................................................................................................................................................................................................................................................................................. 9661
3.9 Removing and installing rear seat backrest................................................................................................................................................................................................................................................................................................................................................................................................................ 9662
3.10 Removing and installing trim for locking mechanism....................................................................................................................................................................................................................................................................................................................................................................................................... 9663
3.11 Removing and installing locking mechanism for rear seat backrest......................................................................................................................................................................................................................................................................................................................................................................................... 9664
3.12 Removing and installing centre armrest................................................................................................................................................................................................................................................................................................................................................................................................................... 9665
3.12.1 Removing and installing centre armrest with load-through hatch..................................................................................................................................................................................................................................................................................................................................................................................... 9665
3.12.2 Removing and installing centre armrest with/without storage compartment............................................................................................................................................................................................................................................................................................................................................................................ 9665
3.13 Removing and installing centre armrest with flap for load-through hatch.................................................................................................................................................................................................................................................................................................................................................................................. 9666
3.14 Removing and installing flap for load-through hatch...................................................................................................................................................................................................................................................................................................................................................................................................... 9666
3.15 Checking floor panel for retainers and wire frame of seat bench and correcting any deformations.......................................................................................................................................................................................................................................................................................................................................................... 9667
3.16 Removing and installing cover for centre bracket......................................................................................................................................................................................................................................................................................................................................................................................................... 9667
3.17 Removing and installing retaining clip................................................................................................................................................................................................................................................................................................................................................................................................................... 9668
3.18 Removing and installing centre bracket................................................................................................................................................................................................................................................................................................................................................................................................................... 9669
3.19 Removing and installing outer bearing.................................................................................................................................................................................................................................................................................................................................................................................................................... 9669
3.20 Removing and installing inner bearing.................................................................................................................................................................................................................................................................................................................................................................................................................... 9670
3.21 Removing and installing side padding..................................................................................................................................................................................................................................................................................................................................................................................................................... 9670
3.22 Removing and installing trim frame....................................................................................................................................................................................................................................................................................................................................................................................................................... 9670
3.23 Removing and installing intermediate padding............................................................................................................................................................................................................................................................................................................................................................................................................. 9671
3.24 Removing and installing trim for cup holder.............................................................................................................................................................................................................................................................................................................................................................................................................. 9671
3.25 Removing and installing cup holder....................................................................................................................................................................................................................................................................................................................................................................................................................... 9672
3.26 Removing and installing storage compartment (cover for backrest bracket with lid)........................................................................................................................................................................................................................................................................................................................................................................ 9673
3.27 Removing and installing cover............................................................................................................................................................................................................................................................................................................................................................................................................................ 9674
3.28 Removing and installing bracket.......................................................................................................................................................................................................................................................................................................................................................................................................................... 9675
3.28.1 Removing and installing bracket - centre armrest with storage compartment.......................................................................................................................................................................................................................................................................................................................................................................... 9675
3.28.2 Removing and installing bracket - centre armrest without storage compartment....................................................................................................................................................................................................................................................................................................................................................................... 9675
3.29 Lid...................................................................................................................................................................................................................................................................................................................................................................................................................................................... 9676
3.30 Removing and installing trim for rear seat backrest bracket.............................................................................................................................................................................................................................................................................................................................................................................................. 9677
3.31 Removing and installing cover for rear seat backrest bracket............................................................................................................................................................................................................................................................................................................................................................................................. 9678
74 – Seat - padding, covers........................................................................................................................................................................................................................................................................................................................................................................................................................................... 9680
1 Covers and padding on front seats............................................................................................................................................................................................................................................................................................................................................................................................................................... 9680
1.1 Exploded view - seat pan cover and padding................................................................................................................................................................................................................................................................................................................................................................................................................ 9680
1.1.1 Exploded view - seat pan cover and padding, seat pan without seat depth adjustment.................................................................................................................................................................................................................................................................................................................................................................. 9680
1.1.2 Exploded view - seat pan cover and padding, seat pan with seat depth adjustment..................................................................................................................................................................................................................................................................................................................................................................... 9682
1.2 Exploded view - backrest cover and padding................................................................................................................................................................................................................................................................................................................................................................................................................ 9684
1.2.1 Exploded view - backrest cover and padding, all seats except super sports seat...................................................................................................................................................................................................................................................................................................................................................................... 9684
1.2.2 Exploded view - backrest cover and padding, super sports seat....................................................................................................................................................................................................................................................................................................................................................................................... 9685
1.3 Exploded view - head restraint cover and padding.......................................................................................................................................................................................................................................................................................................................................................................................................... 9686
1.4 Overview - seat heating elements.......................................................................................................................................................................................................................................................................................................................................................................................................................... 9687
1.4.1 Overview - seat heating element, standard seat...................................................................................................................................................................................................................................................................................................................................................................................................... 9687
1.4.2 Overview - seat heating element, convenience seat................................................................................................................................................................................................................................................................................................................................................................................................... 9688
1.4.3 Overview - seat heating element, sports seat........................................................................................................................................................................................................................................................................................................................................................................................................ 9689
1.4.4 Overview - seat heating element, super sports seat.................................................................................................................................................................................................................................................................................................................................................................................................. 9690
1.5 Overview - backrest heating element....................................................................................................................................................................................................................................................................................................................................................................................................................... 9691
1.5.1 Overview - backrest heating element, standard seat, sports seat..................................................................................................................................................................................................................................................................................................................................................................................... 9691
1.5.2 Overview - backrest heating element, convenience seat............................................................................................................................................................................................................................................................................................................................................................................................... 9692
1.6 Removing and installing seat pan cover and padding........................................................................................................................................................................................................................................................................................................................................................................................................ 9692
1.6.1 Removing and installing seat pan cover and padding - seat pan without seat depth adjustment......................................................................................................................................................................................................................................................................................................................................................... 9692
1.6.2 Removing and installing seat pan cover and padding - seat pan with seat depth adjustment............................................................................................................................................................................................................................................................................................................................................................ 9694
1.7 Removing and installing backrest cover and padding........................................................................................................................................................................................................................................................................................................................................................................................................ 9698
1.7.1 Removing and installing backrest cover and padding - all seats except super sports seat............................................................................................................................................................................................................................................................................................................................................................. 9698
1.7.2 Removing and installing backrest cover and padding - super sports seat.............................................................................................................................................................................................................................................................................................................................................................................. 9702
1.8 Separating seat pan cover and padding..................................................................................................................................................................................................................................................................................................................................................................................................................... 9706
1.8.1 Separating seat pan cover and padding - seat pan without seat depth adjustment...................................................................................................................................................................................................................................................................................................................................................................... 9706
1.8.2 Separating seat pan cover and padding - seat pan with seat depth adjustment......................................................................................................................................................................................................................................................................................................................................................................... 9708
1.9 Separating backrest cover and padding..................................................................................................................................................................................................................................................................................................................................................................................................................... 9711
1.9.1 Separating backrest cover and padding - all seats except super sports seat.......................................................................................................................................................................................................................................................................................................................................................................... 9711
1.9.2 Separating backrest cover and padding - super sports seat........................................................................................................................................................................................................................................................................................................................................................................................... 9713
1.10 Removing and installing head restraint cover and padding................................................................................................................................................................................................................................................................................................................................................................................................. 9714
1.11 Removing and installing seat heating element -Z6-/-Z8-................................................................................................................................................................................................................................................................................................................................................................................................... 9717
1.11.1 Removing and installing seat heating element -Z6-/-Z8- - standard seat............................................................................................................................................................................................................................................................................................................................................................................. 9717
1.11.2 Removing and installing seat heating element -Z6-/-Z8- - convenience seat.......................................................................................................................................................................................................................................................................................................................................................................... 9719
1.11.3 Removing and installing seat heating element -Z6-/-Z8- - sports seat............................................................................................................................................................................................................................................................................................................................................................................... 9720
1.11.4 Removing and installing seat heating element -Z6-/-Z8- - super sports seat......................................................................................................................................................................................................................................................................................................................................................................... 9721
1.12 Removing and installing backrest heating element -Z7-/-Z9-............................................................................................................................................................................................................................................................................................................................................................................................... 9722
1.12.1 Removing and installing backrest heating element -Z7-/-Z9- - standard seat, sports seat............................................................................................................................................................................................................................................................................................................................................................ 9722
1.12.2 Removing and installing backrest heating element -Z7-/-Z9- - convenience seat...................................................................................................................................................................................................................................................................................................................................................................... 9723
2 Covers and padding on rear seats................................................................................................................................................................................................................................................................................................................................................................................................................................ 9724
2.1 Exploded view - cover and padding......................................................................................................................................................................................................................................................................................................................................................................................................................... 9724
2.1.1 Exploded view - seat bench cover and padding........................................................................................................................................................................................................................................................................................................................................................................................................ 9724
2.1.2 Exploded view - backrest cover and padding, rear seat backrest with load-through hatch.............................................................................................................................................................................................................................................................................................................................................................. 9726
2.1.3 Exploded view - backrest cover and padding, rear seat backrest with cover for backrest bracket / storage compartment................................................................................................................................................................................................................................................................................................................................ 9728
2.2 Exploded view - head restraint cover and padding.......................................................................................................................................................................................................................................................................................................................................................................................................... 9730
2.3 Overview - seat heating elements.......................................................................................................................................................................................................................................................................................................................................................................................................................... 9731
2.4 Overview - backrest heating element....................................................................................................................................................................................................................................................................................................................................................................................................................... 9732
2.5 Removing and installing cover and padding................................................................................................................................................................................................................................................................................................................................................................................................................. 9733
2.5.1 Removing and installing seat bench cover and padding................................................................................................................................................................................................................................................................................................................................................................................................ 9733
2.5.2 Removing and installing backrest cover and padding - rear seat backrest with load-through hatch..................................................................................................................................................................................................................................................................................................................................................... 9733
2.5.3 Removing and installing backrest cover and padding - rear seat backrest with cover for rear seat backrest bracket / storage compartment............................................................................................................................................................................................................................................................................................................. 9735
2.6 Removing and installing intermediate padding (backrest with load-through hatch)........................................................................................................................................................................................................................................................................................................................................................................... 9737
2.7 Removing and installing upper and lower padding (backrest with cover for backrest bracket / storage compartment).......................................................................................................................................................................................................................................................................................................................................... 9737
2.8 Detaching seat cover from padding......................................................................................................................................................................................................................................................................................................................................................................................................................... 9738
2.8.1 Detaching seat bench cover from padding............................................................................................................................................................................................................................................................................................................................................................................................................. 9738
2.8.2 Detaching backrest cover from padding - rear seat backrest with load-through hatch.................................................................................................................................................................................................................................................................................................................................................................. 9739
2.8.3 Detaching backrest cover from padding - rear seat backrest with cover for backrest bracket / storage compartment.................................................................................................................................................................................................................................................................................................................................... 9741
2.9 Removing and installing head restraint cover and padding.................................................................................................................................................................................................................................................................................................................................................................................................. 9742
2.10 Removing and installing head restraint trim.............................................................................................................................................................................................................................................................................................................................................................................................................. 9745
2.11 Removing and installing long-arm spring for head restraint............................................................................................................................................................................................................................................................................................................................................................................................... 9745
2.12 Removing and installing seat heating element............................................................................................................................................................................................................................................................................................................................................................................................................. 9745
2.13 Removing and installing backrest heating element......................................................................................................................................................................................................................................................................................................................................................................................................... 9746
Heating__air_conditioning................................................................................................................................................................................................................................................................................................................................................................................................................................................. 9748
00 – Technical data................................................................................................................................................................................................................................................................................................................................................................................................................................................... 9754
1 General notes................................................................................................................................................................................................................................................................................................................................................................................................................................................... 9754
1.1 Type plates............................................................................................................................................................................................................................................................................................................................................................................................................................................... 9755
1.2 Notes on odours in vehicles with air conditioner.......................................................................................................................................................................................................................................................................................................................................................................................................... 9757
1.3 Seat heating and seat ventilation (front)................................................................................................................................................................................................................................................................................................................................................................................................................. 9758
1.4 Heated rear window........................................................................................................................................................................................................................................................................................................................................................................................................................................ 9765
1.5 Notes on control of air conditioner (components in passenger compartment)................................................................................................................................................................................................................................................................................................................................................................................. 9767
1.6 Notes on control of air conditioner (components not located in passenger compartment)..................................................................................................................................................................................................................................................................................................................................................................... 9768
1.6.1 Notes on components not located in passenger compartment - all versions............................................................................................................................................................................................................................................................................................................................................................................. 9768
1.6.2 Notes on components not located in passenger compartment - vehicles with high-voltage system........................................................................................................................................................................................................................................................................................................................................................ 9770
1.7 Notes on refrigerant circuit.............................................................................................................................................................................................................................................................................................................................................................................................................................. 9772
1.8 Notes on heater and air conditioning unit (front)......................................................................................................................................................................................................................................................................................................................................................................................................... 9776
1.9 Notes on operating and display unit....................................................................................................................................................................................................................................................................................................................................................................................................................... 9779
1.10 Overview of control motors of air conditioner............................................................................................................................................................................................................................................................................................................................................................................................................ 9783
2 Safety precautions.............................................................................................................................................................................................................................................................................................................................................................................................................................................. 9786
2.1 Safety precautions when handling refrigerants............................................................................................................................................................................................................................................................................................................................................................................................................. 9786
2.2 Safety precautions when working on high-voltage vehicles.................................................................................................................................................................................................................................................................................................................................................................................................. 9789
2.2.1 Working on vehicles with high-voltage system (hybrid vehicles)...................................................................................................................................................................................................................................................................................................................................................................................... 9789
2.2.2 Visual inspection of high-voltage components and wiring for damage.................................................................................................................................................................................................................................................................................................................................................................................. 9794
2.3 Safety precautions when working on vehicles with start/stop system........................................................................................................................................................................................................................................................................................................................................................................................ 9796
2.4 Safety precautions when using testers and measuring instruments during a road test........................................................................................................................................................................................................................................................................................................................................................................ 9796
2.5 Safety precautions when working on the cooling system..................................................................................................................................................................................................................................................................................................................................................................................................... 9797
3 Repair instructions............................................................................................................................................................................................................................................................................................................................................................................................................................................. 9798
3.1 Rules for cleanliness..................................................................................................................................................................................................................................................................................................................................................................................................................................... 9798
3.2 General notes............................................................................................................................................................................................................................................................................................................................................................................................................................................. 9798
3.3 General repair instructions............................................................................................................................................................................................................................................................................................................................................................................................................................... 9799
3.4 Contact corrosion......................................................................................................................................................................................................................................................................................................................................................................................................................................... 9801
3.5 Checking electrical air conditioner components activated or evaluated via other control units............................................................................................................................................................................................................................................................................................................................................................. 9802
3.6 Checking air conditioner components on vehicles with high-voltage system.................................................................................................................................................................................................................................................................................................................................................................................. 9802
3.7 Checking heating output................................................................................................................................................................................................................................................................................................................................................................................................................................... 9805
3.7.1 Requirements for checking heating output and activation of temperature flaps of air conditioner..................................................................................................................................................................................................................................................................................................................................................... 9805
3.7.2 Checking heating output and activation of temperature flaps of air conditioner...................................................................................................................................................................................................................................................................................................................................................................... 9811
3.7.3 Checking heating output and activation of temperature flaps - basic version......................................................................................................................................................................................................................................................................................................................................................................... 9813
3.7.4 Checking heating output and activation of temperature flaps - deluxe version........................................................................................................................................................................................................................................................................................................................................................................ 9817
3.8 Checking cooling output................................................................................................................................................................................................................................................................................................................................................................................................................................... 9824
3.8.1 Notes on checking cooling output - vehicles without high-voltage system............................................................................................................................................................................................................................................................................................................................................................................. 9824
3.8.2 Requirements for checking cooling output of air conditioner - vehicles without high-voltage system.................................................................................................................................................................................................................................................................................................................................................. 9826
3.8.3 Checking cooling output - vehicles without high-voltage system...................................................................................................................................................................................................................................................................................................................................................................................... 9828
3.8.4 Fault finding if readout does not match specification (required cooling output is not attained) - vehicles without high-voltage system.............................................................................................................................................................................................................................................................................................................. 9833
3.8.5 Fault finding if ice forms at evaporator - vehicles without high-voltage system..................................................................................................................................................................................................................................................................................................................................................................... 9835
3.8.6 Notes on checking cooling output - vehicles with high-voltage system................................................................................................................................................................................................................................................................................................................................................................................ 9837
3.8.7 Requirements for checking cooling output of air conditioner - vehicles with high-voltage system..................................................................................................................................................................................................................................................................................................................................................... 9840
3.8.8 Checking cooling output - vehicles with high-voltage system......................................................................................................................................................................................................................................................................................................................................................................................... 9843
3.8.9 Fault finding if readout does not match specification (required cooling output is not attained) - vehicles with high-voltage system................................................................................................................................................................................................................................................................................................................. 9850
3.8.10 Fault finding if ice forms at evaporator - vehicles with high-voltage system....................................................................................................................................................................................................................................................................................................................................................................... 9853
3.9 Working on refrigerant circuit............................................................................................................................................................................................................................................................................................................................................................................................................................ 9855
3.10 Discharging refrigerant circuit.......................................................................................................................................................................................................................................................................................................................................................................................................................... 9856
3.11 Notes on dust and pollen filter with activated charcoal filter insert.................................................................................................................................................................................................................................................................................................................................................................................... 9856
3.12 Paint repairs on vehicles with air conditioning system................................................................................................................................................................................................................................................................................................................................................................................................... 9858
3.13 Refrigerant circuit seals................................................................................................................................................................................................................................................................................................................................................................................................................................ 9858
4 Technical data.................................................................................................................................................................................................................................................................................................................................................................................................................................................. 9859
4.1 Refrigerant capacities.................................................................................................................................................................................................................................................................................................................................................................................................................................... 9859
4.1.1 Capacities for refrigerant R134a.................................................................................................................................................................................................................................................................................................................................................................................................................... 9859
4.1.2 Capacities for refrigerant R1234yf.................................................................................................................................................................................................................................................................................................................................................................................................................. 9860
4.2 Approved refrigerant oils and refrigerant oil capacities.................................................................................................................................................................................................................................................................................................................................................................................................. 9861
4.2.1 Approved refrigerant oils and refrigerant oil capacities for refrigerant R134a...................................................................................................................................................................................................................................................................................................................................................................... 9861
4.2.2 Approved refrigerant oils for refrigerant R1234yf................................................................................................................................................................................................................................................................................................................................................................................................... 9862
4.2.3 Refrigerant oil capacities in refrigerant circuits for refrigerant R1234yf.......................................................................................................................................................................................................................................................................................................................................................................... 9864
4.3 Oil distribution.......................................................................................................................................................................................................................................................................................................................................................................................................................................... 9865
80 – Heating.......................................................................................................................................................................................................................................................................................................................................................................................................................................................... 9867
1 Overview of fitting locations - heater.......................................................................................................................................................................................................................................................................................................................................................................................................................... 9867
87 – Air conditioning system.......................................................................................................................................................................................................................................................................................................................................................................................................................................... 9868
1 Overview of fitting locations - air conditioner................................................................................................................................................................................................................................................................................................................................................................................................................. 9868
1.1 Overview of fitting locations - components not located in passenger compartment........................................................................................................................................................................................................................................................................................................................................................................... 9868
1.2 Overview of fitting locations - components in passenger compartment (front)............................................................................................................................................................................................................................................................................................................................................................................... 9882
2 Refrigerant circuit............................................................................................................................................................................................................................................................................................................................................................................................................................................. 9897
2.1 System overview - refrigerant circuit..................................................................................................................................................................................................................................................................................................................................................................................................................... 9897
2.1.1 System overview - refrigerant circuit: work not requiring refrigerant circuit to be opened, vehicles without high-voltage system.................................................................................................................................................................................................................................................................................................................... 9898
2.1.2 System overview - refrigerant circuit: work not requiring refrigerant circuit to be opened, vehicles with high-voltage system....................................................................................................................................................................................................................................................................................................................... 9906
2.1.3 System overview - refrigerant circuit: work requiring refrigerant circuit to be opened, vehicles without high-voltage system........................................................................................................................................................................................................................................................................................................................ 9912
2.1.4 System overview - refrigerant circuit: work requiring refrigerant circuit to be opened, vehicles with high-voltage system........................................................................................................................................................................................................................................................................................................................... 9923
2.2 Overview of fitting locations - refrigerant lines......................................................................................................................................................................................................................................................................................................................................................................................................... 9932
2.3 Exploded view - refrigerant lines......................................................................................................................................................................................................................................................................................................................................................................................................................... 9935
2.4 Checking cut-in signal for air conditioner compressor regulating valve -N280-............................................................................................................................................................................................................................................................................................................................................................................. 9937
2.5 Checking activation of air conditioner compressor regulating valve -N280-................................................................................................................................................................................................................................................................................................................................................................................. 9942
2.6 Removing and installing refrigerant pressure and temperature sender -G395-................................................................................................................................................................................................................................................................................................................................................................................ 9942
2.7 Checking refrigerant pressure and temperature sender -G395-............................................................................................................................................................................................................................................................................................................................................................................................... 9943
2.8 Checking pressure signal at refrigerant pressure and temperature sender -G395-............................................................................................................................................................................................................................................................................................................................................................................ 9945
2.9 Removing and installing refrigerant lines to battery cooling module on vehicle floor (front).............................................................................................................................................................................................................................................................................................................................................................. 9946
2.10 Removing and installing refrigerant lines to battery cooling module on vehicle floor (rear).............................................................................................................................................................................................................................................................................................................................................................. 9949
2.11 Removing and installing leadthrough for refrigerant lines into luggage compartment....................................................................................................................................................................................................................................................................................................................................................................... 9953
2.12 Removing and installing refrigerant lines to battery cooling module in luggage compartment............................................................................................................................................................................................................................................................................................................................................................... 9958
2.13 Detaching and attaching refrigerant lines at quick-release couplings..................................................................................................................................................................................................................................................................................................................................................................................... 9963
2.14 Removing and installing refrigerant lines with internal heat exchanger................................................................................................................................................................................................................................................................................................................................................................................... 9969
2.14.1 Removing and installing refrigerant lines with internal heat exchanger - all vehicles except RS models and Audi Q5 hybrid.......................................................................................................................................................................................................................................................................................................................... 9969
2.14.2 Removing and installing refrigerant lines with internal heat exchanger - RS models................................................................................................................................................................................................................................................................................................................................................................. 9972
2.14.3 Removing and installing refrigerant lines with internal heat exchanger - Audi Q5 hybrid............................................................................................................................................................................................................................................................................................................................................................ 9975
2.15 Removing and installing expansion valve.................................................................................................................................................................................................................................................................................................................................................................................................................. 9984
2.16 Removing and installing expansion valve (rear) with refrigerant shut-off valve 2 for hybrid battery -N517-............................................................................................................................................................................................................................................................................................................................................... 9990
2.17 Detaching and attaching refrigerant lines at condenser................................................................................................................................................................................................................................................................................................................................................................................................... 9994
2.17.1 Detaching and attaching refrigerant lines at condenser - all vehicles except RS models............................................................................................................................................................................................................................................................................................................................................................. 9994
2.17.2 Detaching and attaching refrigerant lines at condenser - RS models................................................................................................................................................................................................................................................................................................................................................................................. 9998
2.18 Removing and installing condenser........................................................................................................................................................................................................................................................................................................................................................................................................................10000
2.18.1 Checking version of condenser......................................................................................................................................................................................................................................................................................................................................................................................................................10000
2.18.2 Removing and installing condenser - all vehicles except RS models..................................................................................................................................................................................................................................................................................................................................................................................10002
2.18.3 Removing and installing condenser - RS models......................................................................................................................................................................................................................................................................................................................................................................................................10006
2.19 Removing and installing receiver.........................................................................................................................................................................................................................................................................................................................................................................................................................10008
2.20 Removing and installing desiccant bag/desiccant cartridge................................................................................................................................................................................................................................................................................................................................................................................................10012
2.20.1 Removing and installing desiccant bag/desiccant cartridge - all vehicles except RS models..........................................................................................................................................................................................................................................................................................................................................................10012
2.20.2 Removing and installing desiccant bag/desiccant cartridge - RS models..............................................................................................................................................................................................................................................................................................................................................................................10016
2.21 Differences in service connections depending on refrigerant (R134a or R1234yf)...........................................................................................................................................................................................................................................................................................................................................................................10019
2.22 Removing and installing evacuating and charging valve (low-pressure and high-pressure sides).............................................................................................................................................................................................................................................................................................................................................................10022
2.23 Starting up air conditioner after charging refrigerant circuit...........................................................................................................................................................................................................................................................................................................................................................................................10023
3 Air conditioner compressor......................................................................................................................................................................................................................................................................................................................................................................................................................................10028
3.1 Exploded view - drive unit for air conditioner compressor.................................................................................................................................................................................................................................................................................................................................................................................................10028
3.1.1 Exploded view - drive unit for electrically driven air conditioner compressor.......................................................................................................................................................................................................................................................................................................................................................................10028
3.1.2 Exploded view - drive unit for air conditioner compressor, vehicles with 8-cyl. engine..............................................................................................................................................................................................................................................................................................................................................................10030
3.2 Exploded view - pulley....................................................................................................................................................................................................................................................................................................................................................................................................................................10031
3.2.1 Exploded view - “Denso” air conditioner compressor pulley, version “1”..............................................................................................................................................................................................................................................................................................................................................................................10031
3.2.2 Exploded view - “Denso” air conditioner compressor pulley, version “2”..............................................................................................................................................................................................................................................................................................................................................................................10033
3.2.3 Exploded view - pulley, air conditioner compressor with air conditioning system magnetic clutch -N25-...............................................................................................................................................................................................................................................................................................................................................10036
3.3 Detaching and attaching air conditioner compressor at bracket.............................................................................................................................................................................................................................................................................................................................................................................................10038
3.3.1 Detaching and attaching air conditioner compressor at bracket (mechanically driven air conditioner compressor) - vehicles with 4-cyl. engine........................................................................................................................................................................................................................................................................................................10038
3.3.2 Detaching and attaching air conditioner compressor at bracket (mechanically driven air conditioner compressor) - vehicles with 6-cyl. TDI engine....................................................................................................................................................................................................................................................................................................10041
3.3.3 Detaching and attaching air conditioner compressor at bracket (electrically driven).................................................................................................................................................................................................................................................................................................................................................................10044
3.4 Detaching and attaching refrigerant lines at air conditioner compressor...................................................................................................................................................................................................................................................................................................................................................................................10053
3.4.1 Detaching and attaching refrigerant lines at air conditioner compressor - vehicles with 4-cyl. engine...............................................................................................................................................................................................................................................................................................................................................10053
3.4.2 Detaching and attaching refrigerant lines at air conditioner compressor - vehicles with 6-cyl. engine...............................................................................................................................................................................................................................................................................................................................................10058
3.4.3 Detaching and attaching refrigerant lines at air conditioner compressor - vehicles with 8-cyl. FSI engine...........................................................................................................................................................................................................................................................................................................................................10062
3.5 Removing and installing air conditioner compressor........................................................................................................................................................................................................................................................................................................................................................................................................10066
3.5.1 Removing and installing air conditioner compressor (mechanically driven) - vehicles with 4-cyl. engine..............................................................................................................................................................................................................................................................................................................................................10066
3.5.2 Removing and installing air conditioner compressor (electrically driven) - vehicles with 4-cyl. engine..............................................................................................................................................................................................................................................................................................................................................10069
3.5.3 Removing and installing air conditioner compressor - vehicles with 6-cyl. TDI engine................................................................................................................................................................................................................................................................................................................................................................10076
3.5.4 Removing and installing air conditioner compressor - vehicles with 6-cyl. petrol engine.............................................................................................................................................................................................................................................................................................................................................................10083
3.5.5 Removing and installing air conditioner compressor - vehicles with 8-cyl. FSI engine except RS models...............................................................................................................................................................................................................................................................................................................................................10089
3.5.6 Removing and installing air conditioner compressor - vehicles with 8-cyl. FSI engine, RS models.....................................................................................................................................................................................................................................................................................................................................................10102
3.6 Preparations for renewing pulley..........................................................................................................................................................................................................................................................................................................................................................................................................................10113
3.7 Removing and installing pulley............................................................................................................................................................................................................................................................................................................................................................................................................................10113
3.7.1 Removing and installing pulley - “Denso” air conditioner compressor, version “1”....................................................................................................................................................................................................................................................................................................................................................................10113
3.7.2 Removing and installing pulley - “Denso” air conditioner compressor, version “2”....................................................................................................................................................................................................................................................................................................................................................................10115
3.7.3 Removing and installing pulley, air conditioner compressor with air conditioning system magnetic clutch -N25-.......................................................................................................................................................................................................................................................................................................................................10117
3.8 Unfastening and securing air conditioner compressor drive shaft...........................................................................................................................................................................................................................................................................................................................................................................................10119
3.9 Removing and installing air conditioner compressor drive shaft............................................................................................................................................................................................................................................................................................................................................................................................10119
3.10 Removing and installing drive plate with overload protection.............................................................................................................................................................................................................................................................................................................................................................................................10120
3.11 Checking and adjusting concentricity of drive plate with overload protection.............................................................................................................................................................................................................................................................................................................................................................................10121
3.12 Removing and installing drive plate at air conditioner compressor........................................................................................................................................................................................................................................................................................................................................................................................10121
3.13 Removing and installing drive plate with roller bearing..................................................................................................................................................................................................................................................................................................................................................................................................10122
4 Control motors..................................................................................................................................................................................................................................................................................................................................................................................................................................................10124
4.1 Overview of fitting locations - control motors (front)....................................................................................................................................................................................................................................................................................................................................................................................................10124
4.1.1 Overview of fitting locations - control motors (front), “basic” version.............................................................................................................................................................................................................................................................................................................................................................................10124
4.1.2 Overview of fitting locations - control motors (front), “deluxe” version............................................................................................................................................................................................................................................................................................................................................................................10133
4.2 Removing and installing temperature flap control motor -V68-/rear temperature flap control motor -V137-...................................................................................................................................................................................................................................................................................................................................................10138
4.3 Removing and installing air flow flap control motor -V71-.................................................................................................................................................................................................................................................................................................................................................................................................10142
4.4 Removing and installing centre vent control motor -V102-..................................................................................................................................................................................................................................................................................................................................................................................................10144
4.5 Removing and installing defroster flap control motor -V107-...............................................................................................................................................................................................................................................................................................................................................................................................10146
4.6 Removing and installing left footwell flap control motor -V108-/footwell flap control motor -V261-........................................................................................................................................................................................................................................................................................................................................................10148
4.7 Removing and installing right footwell flap control motor -V109-..........................................................................................................................................................................................................................................................................................................................................................................................10150
4.8 Removing and installing left centre vent control motor -V110-.............................................................................................................................................................................................................................................................................................................................................................................................10152
4.9 Removing and installing right centre vent control motor -V111-............................................................................................................................................................................................................................................................................................................................................................................................10155
4.10 Removing and installing air recirculation flap control motor -V113-......................................................................................................................................................................................................................................................................................................................................................................................10157
4.11 Removing and installing left temperature flap control motor -V158-.......................................................................................................................................................................................................................................................................................................................................................................................10159
4.12 Removing and installing right temperature flap control motor -V159-......................................................................................................................................................................................................................................................................................................................................................................................10163
4.13 Removing and installing air recirculation flap 1 control motor for hybrid battery -V479-.................................................................................................................................................................................................................................................................................................................................................................10165
4.14 Removing and installing air recirculation flap 2 control motor for hybrid battery -V480-.................................................................................................................................................................................................................................................................................................................................................................10168
4.15 Removing and installing retaining plate (left-side) with control motors -V108- and -V110-................................................................................................................................................................................................................................................................................................................................................................10171
4.16 Removing and installing retaining plate (right-side) with control motors -V109- and -V111-...............................................................................................................................................................................................................................................................................................................................................................10174
4.17 Removing and installing retaining plate (left-side) with footwell flap control motor -V261-..............................................................................................................................................................................................................................................................................................................................................................10177
4.18 Dismantling and assembling retaining plate (left-side) with control motors -V108- and -V110-.............................................................................................................................................................................................................................................................................................................................................................10179
4.19 Dismantling and assembling retaining plate (right-side) with control motors -V109- and -V111-............................................................................................................................................................................................................................................................................................................................................................10181
4.20 Dismantling and assembling retaining plate (left-side) with footwell flap control motor -V261-...........................................................................................................................................................................................................................................................................................................................................................10182
5 Heater and air conditioning unit (front)........................................................................................................................................................................................................................................................................................................................................................................................................................10183
5.1 Exploded view - attachments for heater and air conditioning unit and air intake box.......................................................................................................................................................................................................................................................................................................................................................................10183
5.1.1 Exploded view - attachments for heater and air conditioning unit and air intake box, “basic” version................................................................................................................................................................................................................................................................................................................................................10183
5.1.2 Exploded view - attachments for heater and air conditioning unit and air intake box, “deluxe” version...............................................................................................................................................................................................................................................................................................................................................10187
5.2 Exploded view - flaps and partitions in air distribution housing..........................................................................................................................................................................................................................................................................................................................................................................................10191
5.2.1 Exploded view - flaps and partitions in air distribution housing, “basic” version...................................................................................................................................................................................................................................................................................................................................................................10191
5.2.2 Exploded view - flaps and partitions in air distribution housing, “deluxe” version..................................................................................................................................................................................................................................................................................................................................................................10192
5.3 Exploded view - air intake box of heater and air conditioning unit........................................................................................................................................................................................................................................................................................................................................................................................10194
5.4 Exploded view - evaporator housing........................................................................................................................................................................................................................................................................................................................................................................................................................10199
5.5 Removing and installing evaporator........................................................................................................................................................................................................................................................................................................................................................................................................................10203
5.6 Removing and installing evaporator housing................................................................................................................................................................................................................................................................................................................................................................................................................10220
5.7 Cleaning evaporator.......................................................................................................................................................................................................................................................................................................................................................................................................................................10225
5.7.1 Cleaning evaporator with an ultrasonic A/C cleaner..................................................................................................................................................................................................................................................................................................................................................................................................10225
5.7.2 Cleaning evaporator using pressure-feed spray gun -V.A.G 1538- and spray lance......................................................................................................................................................................................................................................................................................................................................................................10227
5.8 Checking auxiliary air heater element -Z35-...............................................................................................................................................................................................................................................................................................................................................................................................................10234
5.9 Removing and installing auxiliary air heater element -Z35-................................................................................................................................................................................................................................................................................................................................................................................................10239
5.10 Checking heating output and activation of temperature flaps of air conditioner...........................................................................................................................................................................................................................................................................................................................................................................10242
5.11 Removing and installing heater and air conditioning unit.................................................................................................................................................................................................................................................................................................................................................................................................10248
5.12 Removing and installing air intake box of heater and air conditioning unit...............................................................................................................................................................................................................................................................................................................................................................................10264
5.13 Removing and installing heater housing (left-side, with temperature flaps)...............................................................................................................................................................................................................................................................................................................................................................................10268
5.14 Removing and installing heater housing (right-side, with temperature flaps)..............................................................................................................................................................................................................................................................................................................................................................................10272
5.14.1 Removing and installing heater housing, right-side (with retaining plate, right-side, for control motors detached).................................................................................................................................................................................................................................................................................................................................10272
5.14.2 Removing and installing heater housing (right-side) together with retaining plate (right-side) for control motors..................................................................................................................................................................................................................................................................................................................................10276
5.15 Removing and installing dust and pollen filter...........................................................................................................................................................................................................................................................................................................................................................................................................10282
5.16 Removing and installing fresh air blower -V2-............................................................................................................................................................................................................................................................................................................................................................................................................10283
5.17 Removing and installing fresh air blower control unit -J126-.............................................................................................................................................................................................................................................................................................................................................................................................10286
5.18 Preparations for removing heat exchanger.................................................................................................................................................................................................................................................................................................................................................................................................................10288
5.19 Removing and installing heat exchanger...................................................................................................................................................................................................................................................................................................................................................................................................................10294
5.20 Removing and installing condensation drain...............................................................................................................................................................................................................................................................................................................................................................................................................10302
5.21 Checking condensation drain..............................................................................................................................................................................................................................................................................................................................................................................................................................10303
6 Air duct system.................................................................................................................................................................................................................................................................................................................................................................................................................................................10305
6.1 Exploded view - routing of air flow and air distribution in passenger compartment.........................................................................................................................................................................................................................................................................................................................................................................10305
6.2 Air intake and air outlet openings........................................................................................................................................................................................................................................................................................................................................................................................................................10309
6.3 Removing and installing footwell vent (driver side).......................................................................................................................................................................................................................................................................................................................................................................................................10316
6.4 Removing and installing footwell vent (passenger side)....................................................................................................................................................................................................................................................................................................................................................................................................10317
6.5 Installing plugs in air duct to centre vent...............................................................................................................................................................................................................................................................................................................................................................................................................10317
6.6 Removing and installing forced ventilation vents in passenger compartment.................................................................................................................................................................................................................................................................................................................................................................................10318
6.7 Checking forced ventilation vents in passenger compartment................................................................................................................................................................................................................................................................................................................................................................................................10319
6.8 Removing and installing fresh air intake..................................................................................................................................................................................................................................................................................................................................................................................................................10323
6.9 Removing and installing intake duct.......................................................................................................................................................................................................................................................................................................................................................................................................................10327
6.10 Removing and installing plenum chamber water drain.......................................................................................................................................................................................................................................................................................................................................................................................................10328
6.11 Checking plenum chamber water drain......................................................................................................................................................................................................................................................................................................................................................................................................................10330
6.12 Cleaning plenum chamber water drain......................................................................................................................................................................................................................................................................................................................................................................................................................10334
6.13 Removing and installing dash panel vents and rear vent...................................................................................................................................................................................................................................................................................................................................................................................................10338
6.14 Connection for glove box cooling at air intake box.......................................................................................................................................................................................................................................................................................................................................................................................................10338
6.15 Masking slots of air duct to vents (rear)................................................................................................................................................................................................................................................................................................................................................................................................................10339
7 Coolant circuit.................................................................................................................................................................................................................................................................................................................................................................................................................................................10341
7.1 Layout, activation and operation of coolant shut-off valve -N82-/-N422-...................................................................................................................................................................................................................................................................................................................................................................................10341
7.2 Layout, activation and operation of coolant circulation pump -V50- (coolant pump -V36-)...................................................................................................................................................................................................................................................................................................................................................................10345
7.2.1 Layout, activation and operation of coolant circulation pump -V50- (coolant pump -V36-) - vehicles with 4-cyl. or 6-cyl. engine.....................................................................................................................................................................................................................................................................................................................10345
7.2.2 Layout, activation and operation of coolant circulation pump -V50- (coolant pump -V36-) - vehicles with 6-cyl. petrol engine........................................................................................................................................................................................................................................................................................................................10347
8 Operating and display unit......................................................................................................................................................................................................................................................................................................................................................................................................................................10351
8.1 Assignment of operating and display unit..................................................................................................................................................................................................................................................................................................................................................................................................................10351
8.2 Removing and installing operating and display unit........................................................................................................................................................................................................................................................................................................................................................................................................10359
8.3 Removing and installing temperature sensor blower.........................................................................................................................................................................................................................................................................................................................................................................................................10362
9 Further control components......................................................................................................................................................................................................................................................................................................................................................................................................................................10363
9.1 Removing and installing sunlight penetration photosensor -G107-...........................................................................................................................................................................................................................................................................................................................................................................................10363
9.2 Operation of air quality sensor -G238-....................................................................................................................................................................................................................................................................................................................................................................................................................10365
9.3 Checking air quality sensor -G238-........................................................................................................................................................................................................................................................................................................................................................................................................................10368
9.4 Removing and installing air quality sensor -G238-/humidity sender in fresh air intake duct -G657-.........................................................................................................................................................................................................................................................................................................................................................10378
9.5 Removing and installing ambient temperature sensor -G17-..................................................................................................................................................................................................................................................................................................................................................................................................10382
9.6 Removing and installing centre vent temperature sender -G191-.............................................................................................................................................................................................................................................................................................................................................................................................10383
9.7 Removing and installing footwell vent temperature sender -G192-/left footwell vent temperature sender -G261-..............................................................................................................................................................................................................................................................................................................................................10383
9.8 Removing and installing right footwell vent temperature sender -G262-.....................................................................................................................................................................................................................................................................................................................................................................................10384
9.9 Removing and installing evaporator output temperature sender -G263-.......................................................................................................................................................................................................................................................................................................................................................................................10384
9.10 Removing and installing humidity sender -G355-...........................................................................................................................................................................................................................................................................................................................................................................................................10385
9.10.1 Removing and installing humidity sender -G355- - vehicles without main beam assist.................................................................................................................................................................................................................................................................................................................................................................10385
9.10.2 Removing and installing humidity sender -G355- - vehicles with main beam assist....................................................................................................................................................................................................................................................................................................................................................................10387
9.11 Removing and installing rain and light sensor -G397-.....................................................................................................................................................................................................................................................................................................................................................................................................10388
9.12 Removing and installing front left chest vent temperature sensor -G385-..................................................................................................................................................................................................................................................................................................................................................................................10389
9.13 Removing and installing front right chest vent temperature sensor -G386-.................................................................................................................................................................................................................................................................................................................................................................................10390
9.14 Operation of humidity sender in fresh air intake duct -G657-.............................................................................................................................................................................................................................................................................................................................................................................................10391
9.15 Checking humidity sender in fresh air intake duct -G657-.................................................................................................................................................................................................................................................................................................................................................................................................10392
10 Battery cooling module.........................................................................................................................................................................................................................................................................................................................................................................................................................................10393
10.1 Overview of fitting locations - components not located in passenger compartment..........................................................................................................................................................................................................................................................................................................................................................................10393
10.2 Overview of fitting locations - components in passenger compartment (rear)...............................................................................................................................................................................................................................................................................................................................................................................10397
10.3 Exploded view - battery cooling module...................................................................................................................................................................................................................................................................................................................................................................................................................10399
10.4 Air intake, air outlet and routing of air flow at battery cooling module.................................................................................................................................................................................................................................................................................................................................................................................10402
10.5 Exploded view - air ducts................................................................................................................................................................................................................................................................................................................................................................................................................................10404
10.6 Removing and installing refrigerant shut-off valve 1 for hybrid battery -N516-...........................................................................................................................................................................................................................................................................................................................................................................10407
10.7 Removing and installing air outlet duct (rear) for drive battery -A2-....................................................................................................................................................................................................................................................................................................................................................................................10410
10.8 Removing and installing air outlet duct (front) for drive battery -A2-...................................................................................................................................................................................................................................................................................................................................................................................10412
10.9 Removing and installing air inlet duct for drive battery -A2-............................................................................................................................................................................................................................................................................................................................................................................................10414
10.10 Removing and installing air ducts (left and right) at drive battery -A2-................................................................................................................................................................................................................................................................................................................................................................................10416
10.11 Moving battery cooling module to service position.......................................................................................................................................................................................................................................................................................................................................................................................................10418
10.12 Removing and installing battery cooling module..........................................................................................................................................................................................................................................................................................................................................................................................................10420
10.13 Removing and installing battery fan 1 -V457-............................................................................................................................................................................................................................................................................................................................................................................................................10423
10.14 Removing and installing temperature sensor before evaporator for hybrid battery -G756-..................................................................................................................................................................................................................................................................................................................................................................10425
10.15 Removing and installing temperature sensor after evaporator for hybrid battery -G757-...................................................................................................................................................................................................................................................................................................................................................................10427
10.16 Removing and installing condensation drain..............................................................................................................................................................................................................................................................................................................................................................................................................10429
10.17 Checking condensation drain.............................................................................................................................................................................................................................................................................................................................................................................................................................10431
Maintenance...............................................................................................................................................................................................................................................................................................................................................................................................................................................................10434
1 General information.................................................................................................................................................................................................................................................................................................................................................................................................................................................10440
1.1 --- Change history ---........................................................................................................................................................................................................................................................................................................................................................................................................................................10440
1.2 Engine number.................................................................................................................................................................................................................................................................................................................................................................................................................................................10440
1.2.1 4-cyl. petrol engine 1.8 ltr. TFSI......................................................................................................................................................................................................................................................................................................................................................................................................................10441
1.2.2 4-cyl. petrol engine 2.0 ltr. TFSI......................................................................................................................................................................................................................................................................................................................................................................................................................10441
1.2.3 6-cyl. petrol engine 3.0 ltr. TFSI/3.2 ltr. FSI.........................................................................................................................................................................................................................................................................................................................................................................................................10442
1.2.4 8-cyl. petrol engine 4.2 ltr. FSI.......................................................................................................................................................................................................................................................................................................................................................................................................................10442
1.2.5 4-cyl. diesel engine 2.0 ltr. TDI.......................................................................................................................................................................................................................................................................................................................................................................................................................10442
1.2.6 6-cyl. diesel engine 2.7 ltr. TDI/3.0 ltr. TDI..........................................................................................................................................................................................................................................................................................................................................................................................................10443
1.3 Vehicle identification number.................................................................................................................................................................................................................................................................................................................................................................................................................................10443
1.4 Vehicle data sticker..........................................................................................................................................................................................................................................................................................................................................................................................................................................10443
2 Preparations........................................................................................................................................................................................................................................................................................................................................................................................................................................................10445
2.1 Vehicle: raising..............................................................................................................................................................................................................................................................................................................................................................................................................................................10445
2.2 Engine cover panel: removing and installing...................................................................................................................................................................................................................................................................................................................................................................................................................10447
2.2.1 4-cyl. petrol engine 1.8 ltr. TFSI/2.0 ltr. TFSI (version 1)............................................................................................................................................................................................................................................................................................................................................................................................10447
2.2.2 4-cyl. petrol engine 1.8 ltr. TFSI/2.0 ltr. TFSI (version 2)............................................................................................................................................................................................................................................................................................................................................................................................10447
2.2.3 6-cyl. petrol engine 3.0 ltr. TFSI (version 1)..........................................................................................................................................................................................................................................................................................................................................................................................................10448
2.2.4 6-cyl. petrol engine 3.0 ltr. TFSI (version 2)..........................................................................................................................................................................................................................................................................................................................................................................................................10448
2.2.5 6-cyl. petrol engine 3.2 ltr. FSI.......................................................................................................................................................................................................................................................................................................................................................................................................................10449
2.2.6 8-cyl. petrol engine 4.2 ltr. FSI (version 1)...........................................................................................................................................................................................................................................................................................................................................................................................................10449
2.2.7 8-cyl. petrol engine 4.2 ltr. FSI (version 2)...........................................................................................................................................................................................................................................................................................................................................................................................................10449
2.2.8 4-cyl. diesel engine 2.0 ltr. TDI (version 1)...........................................................................................................................................................................................................................................................................................................................................................................................................10450
2.2.9 4-cyl. diesel engine 2.0 ltr. TDI (version 2)...........................................................................................................................................................................................................................................................................................................................................................................................................10450
2.2.10 4-cyl. diesel engine 2.0 ltr. TDI (version 3)..........................................................................................................................................................................................................................................................................................................................................................................................................10450
2.2.11 6-cyl. diesel engine 2.7 ltr. TDI/3.0 ltr. TDI.........................................................................................................................................................................................................................................................................................................................................................................................................10451
2.3 Noise insulation: removing and installing.....................................................................................................................................................................................................................................................................................................................................................................................................................10451
2.3.1 Front noise insulation: all models except RS 5..........................................................................................................................................................................................................................................................................................................................................................................................................10451
2.3.2 Front noise insulation: RS 5............................................................................................................................................................................................................................................................................................................................................................................................................................10452
2.3.3 Rear noise insulation: all models except RS 5...........................................................................................................................................................................................................................................................................................................................................................................................................10454
2.3.4 Rear noise insulation: RS 5.............................................................................................................................................................................................................................................................................................................................................................................................................................10454
2.4 Window regulators: activating automatic open/close function...................................................................................................................................................................................................................................................................................................................................................................................................10455
2.5 Vehicle diagnostic tester: connecting.........................................................................................................................................................................................................................................................................................................................................................................................................................10455
3 Maintenance.........................................................................................................................................................................................................................................................................................................................................................................................................................................................10458
3.1 Diesel particulate filter: reading out ash deposit volume.....................................................................................................................................................................................................................................................................................................................................................................................................10461
3.2 Event memory: reading out and erasing.........................................................................................................................................................................................................................................................................................................................................................................................................................10462
3.3 Navigation system (MMI basic): releasing eject button and running CD for languages............................................................................................................................................................................................................................................................................................................................................................................10463
3.4 MMI navigation system: loading navigation CD/DVD..............................................................................................................................................................................................................................................................................................................................................................................................................10463
3.5 Service interval display: resetting service...................................................................................................................................................................................................................................................................................................................................................................................................................10463
3.6 Transport mode: deactivating..................................................................................................................................................................................................................................................................................................................................................................................................................................10464
3.7 Transport mode: checking activation and activating if necessary...............................................................................................................................................................................................................................................................................................................................................................................................10464
3.7.1 Checking transport mode.................................................................................................................................................................................................................................................................................................................................................................................................................................10464
3.7.2 Activating transport mode...............................................................................................................................................................................................................................................................................................................................................................................................................................10464
3.8 Battery: reading out status and sending diagnostic log........................................................................................................................................................................................................................................................................................................................................................................................................10465
3.9 Battery: checking that battery and battery cables are securely fitted.........................................................................................................................................................................................................................................................................................................................................................................................10466
3.10 Battery: checking electrolyte level..........................................................................................................................................................................................................................................................................................................................................................................................................................10467
3.10.1 Battery without magic eye..............................................................................................................................................................................................................................................................................................................................................................................................................................10467
3.10.2 Battery with magic eye.................................................................................................................................................................................................................................................................................................................................................................................................................................10468
3.11 Battery: connecting stationary battery charging unit (min. 30A, charging voltage max. 14.8 V on IV characteristic curve).....................................................................................................................................................................................................................................................................................................................................10469
3.12 Battery: determining and recording state of charge (SOC).....................................................................................................................................................................................................................................................................................................................................................................................................10471
3.12.1 Vehicles with transport mode ON........................................................................................................................................................................................................................................................................................................................................................................................................................10471
3.12.2 Vehicles with transport mode OFF.......................................................................................................................................................................................................................................................................................................................................................................................................................10472
3.12.3 Measuring no load voltage of battery...................................................................................................................................................................................................................................................................................................................................................................................................................10473
3.13 Mirror hanger indicating defective battery: renewing battery on affected vehicles............................................................................................................................................................................................................................................................................................................................................................................10475
3.14 Brake fluid: changing........................................................................................................................................................................................................................................................................................................................................................................................................................................10475
3.15 Brake fluid (vehicles older than 12 months): changing........................................................................................................................................................................................................................................................................................................................................................................................................10480
3.16 Brake fluid: checking fluid level............................................................................................................................................................................................................................................................................................................................................................................................................................10480
3.17 Brake system: checking condition of brake hoses, and checking that caps are fitted on bleeder screws.........................................................................................................................................................................................................................................................................................................................................................10480
3.18 Brake pads: checking thickness...............................................................................................................................................................................................................................................................................................................................................................................................................................10481
3.19 Brake discs: checking for surface rust and operating brakes to clean if necessary............................................................................................................................................................................................................................................................................................................................................................................10482
3.19.1 Checking brake discs...................................................................................................................................................................................................................................................................................................................................................................................................................................10482
3.19.2 Operating brakes to clean brake discs..................................................................................................................................................................................................................................................................................................................................................................................................................10483
3.20 Parking brake: releasing.....................................................................................................................................................................................................................................................................................................................................................................................................................................10483
3.20.1 Mechanical parking brake...............................................................................................................................................................................................................................................................................................................................................................................................................................10483
3.20.2 Electromechanical parking brake........................................................................................................................................................................................................................................................................................................................................................................................................................10483
3.21 Tyres: checking condition and wear pattern, and checking and recording tread depth...........................................................................................................................................................................................................................................................................................................................................................................10483
3.22 Tyres: checking tyre pressures and adjusting if necessary....................................................................................................................................................................................................................................................................................................................................................................................................10485
3.22.1 Front and rear axle....................................................................................................................................................................................................................................................................................................................................................................................................................................10485
3.22.2 Spare wheel and temporary spare wheel..................................................................................................................................................................................................................................................................................................................................................................................................................10485
3.23 Tyres (except spare wheel): checking tyre pressures and adjusting to 3.5 bar if necessary....................................................................................................................................................................................................................................................................................................................................................................10486
3.24 Tyre Pressure Loss Indicator: storing changed tyre pressures.................................................................................................................................................................................................................................................................................................................................................................................................10486
3.24.1 Storing tyre pressures via MMI (version 1).............................................................................................................................................................................................................................................................................................................................................................................................................10486
3.24.2 Storing tyre pressures via MMI (version 2).............................................................................................................................................................................................................................................................................................................................................................................................................10486
3.25 Tyre repair kit: checking that set is complete, and checking and recording expiry date.......................................................................................................................................................................................................................................................................................................................................................................10487
3.26 Wheel bolts: tightening to specified torque..................................................................................................................................................................................................................................................................................................................................................................................................................10487
3.27 Suspension struts on front and rear axle: removing locking elements..........................................................................................................................................................................................................................................................................................................................................................................................10488
3.27.1 Suspension struts on front axle........................................................................................................................................................................................................................................................................................................................................................................................................................10488
3.27.2 Suspension struts on rear axle.........................................................................................................................................................................................................................................................................................................................................................................................................................10489
3.27.3 Pressing in bump stop..................................................................................................................................................................................................................................................................................................................................................................................................................................10490
3.28 Components of front and rear axles: checking play, secure attachment and protective boots....................................................................................................................................................................................................................................................................................................................................................................10490
3.28.1 Front axle.............................................................................................................................................................................................................................................................................................................................................................................................................................................10490
3.28.2 Rear axle..............................................................................................................................................................................................................................................................................................................................................................................................................................................10492
3.29 Engine, gearbox, final drive and steering: checking for leaks and damage.....................................................................................................................................................................................................................................................................................................................................................................................10493
3.30 Vehicle (from below): checking for damage....................................................................................................................................................................................................................................................................................................................................................................................................................10493
3.31 Underbody: checking trim, wheel housing liners, side members and pipes/wiring for damage, and checking that they are properly secured........................................................................................................................................................................................................................................................................................................................10493
3.32 Roof insert: checking operation..............................................................................................................................................................................................................................................................................................................................................................................................................................10494
3.33 Roof insert - tilting sunroof: cleaning and lubricating......................................................................................................................................................................................................................................................................................................................................................................................................10494
3.34 Roof insert - sliding/tilting sunroof: cleaning and lubricating..............................................................................................................................................................................................................................................................................................................................................................................................10495
3.35 Rear spoiler hinges: lubricating.............................................................................................................................................................................................................................................................................................................................................................................................................................10498
3.36 Bonnet arrester hook: lubricating............................................................................................................................................................................................................................................................................................................................................................................................................................10498
3.37 Windscreen washer system: checking spray pattern and adjusting if necessary..................................................................................................................................................................................................................................................................................................................................................................................10499
3.37.1 Checking spray pattern on windscreen...................................................................................................................................................................................................................................................................................................................................................................................................................10499
3.37.2 Adjusting windscreen washer jets.......................................................................................................................................................................................................................................................................................................................................................................................................................10499
3.38 Wiper blades: checking for damage............................................................................................................................................................................................................................................................................................................................................................................................................................10499
3.39 Headlight washer system: checking operation..................................................................................................................................................................................................................................................................................................................................................................................................................10500
3.40 Headlights: checking for correct adjustment..................................................................................................................................................................................................................................................................................................................................................................................................................10500
3.41 Headlights and reversing lights, side lights, number plate lights, turn signals, hazard warning lights: checking operation...................................................................................................................................................................................................................................................................................................................................10501
3.42 Luggage compartment lighting: checking operation.............................................................................................................................................................................................................................................................................................................................................................................................................10502
3.42.1 A5 Coupé...............................................................................................................................................................................................................................................................................................................................................................................................................................................10502
3.42.2 A5 Sportback...........................................................................................................................................................................................................................................................................................................................................................................................................................................10502
3.43 Luggage compartment: removing protective film and felt pieces................................................................................................................................................................................................................................................................................................................................................................................................10503
3.44 Glove box light, interior lighting and reading light: checking operation.....................................................................................................................................................................................................................................................................................................................................................................................10503
3.45 Horn: checking operation.....................................................................................................................................................................................................................................................................................................................................................................................................................................10503
3.46 Front passenger airbag: checking key switch on / off and setting to "on".....................................................................................................................................................................................................................................................................................................................................................................................10504
3.47 Owner's literature: checking that all documents are present..................................................................................................................................................................................................................................................................................................................................................................................................10504
3.48 Service Schedule: affixing vehicle data sticker..............................................................................................................................................................................................................................................................................................................................................................................................................10504
3.49 Service Schedule: entering Delivery Inspection...............................................................................................................................................................................................................................................................................................................................................................................................................10504
3.50 Seat belts: checking that retaining rivets are fitted, and checking locking action of automatic belt retractor...............................................................................................................................................................................................................................................................................................................................................10505
3.51 Vehicle interior: removing protective covers for seats and carpet............................................................................................................................................................................................................................................................................................................................................................................................10505
3.52 Vehicle interior: checking that it is clean and cleaning if necessary........................................................................................................................................................................................................................................................................................................................................................................................10505
3.53 Vehicle interior: removing any objects other than those protecting interior surfaces.........................................................................................................................................................................................................................................................................................................................................................................10505
3.54 Vehicle interior and exterior: checking for and documenting any damage.......................................................................................................................................................................................................................................................................................................................................................................................10505
3.55 Instrument cluster: checking warning lamps...................................................................................................................................................................................................................................................................................................................................................................................................................10506
3.56 Warning triangle: checking availability......................................................................................................................................................................................................................................................................................................................................................................................................................10506
3.57 First-aid kit: checking and recording expiry date............................................................................................................................................................................................................................................................................................................................................................................................................10506
3.58 Vehicle keys: checking operation and recording number of keys given to customer..............................................................................................................................................................................................................................................................................................................................................................................10506
3.59 Vehicle key: removing from ignition lock.....................................................................................................................................................................................................................................................................................................................................................................................................................10507
3.60 Vehicle key(s), wheel covers and owner's literature: checking availability and recording number present......................................................................................................................................................................................................................................................................................................................................................10507
3.61 Sun visors: checking that they are folded up and folding up if necessary.....................................................................................................................................................................................................................................................................................................................................................................................10507
3.62 Luggage compartment cover and sun blind: checking that they are rolled up and rolling up if necessary........................................................................................................................................................................................................................................................................................................................................................10507
3.63 Engine oil: draining.........................................................................................................................................................................................................................................................................................................................................................................................................................................10507
3.63.1 4-cyl. diesel engine 2.0 ltr. TDI......................................................................................................................................................................................................................................................................................................................................................................................................................10508
3.64 Engine oil: extracting.......................................................................................................................................................................................................................................................................................................................................................................................................................................10508
3.65 Engine oil: renewing oil filter..............................................................................................................................................................................................................................................................................................................................................................................................................................10509
3.65.1 4-cyl. petrol engine 1.8 ltr. TFSI/2.0 ltr. TFSI (version 1)...........................................................................................................................................................................................................................................................................................................................................................................................10509
3.65.2 4-cyl. petrol engine 1.8 ltr. TFSI/2.0 ltr. TFSI (version 2)...........................................................................................................................................................................................................................................................................................................................................................................................10510
3.65.3 6-cyl. petrol engine 3.0 ltr. TFSI (version 1).........................................................................................................................................................................................................................................................................................................................................................................................................10511
3.65.4 6-cyl. petrol engine 3.0 ltr. TFSI/3.2 ltr. FSI (version 2)............................................................................................................................................................................................................................................................................................................................................................................................10512
3.65.5 8-cyl. petrol engine 4.2 ltr. FSI......................................................................................................................................................................................................................................................................................................................................................................................................................10513
3.65.6 4-cyl. diesel engine 2.0 ltr. TDI (version 1)..........................................................................................................................................................................................................................................................................................................................................................................................................10514
3.65.7 4-cyl. diesel engine 2.0 ltr. TDI (version 2)..........................................................................................................................................................................................................................................................................................................................................................................................................10515
3.65.8 4-cyl. diesel engine 2.0 ltr. TDI (version 3)..........................................................................................................................................................................................................................................................................................................................................................................................................10516
3.65.9 6-cyl. diesel engine 2.7 ltr. TDI/3.0 ltr. TDI (version 1).............................................................................................................................................................................................................................................................................................................................................................................................10517
3.65.10 6-cyl. diesel engine 3.0 ltr. TDI (version 2).........................................................................................................................................................................................................................................................................................................................................................................................................10518
3.66 Engine oil: filling up.......................................................................................................................................................................................................................................................................................................................................................................................................................................10519
3.67 Engine oil: checking oil level and correcting if necessary...................................................................................................................................................................................................................................................................................................................................................................................................10520
3.67.1 Checking oil level with dipstick.......................................................................................................................................................................................................................................................................................................................................................................................................................10521
3.67.2 Checking oil level on MMI..............................................................................................................................................................................................................................................................................................................................................................................................................................10521
3.68 Poly V-belts for ancillaries: checking.......................................................................................................................................................................................................................................................................................................................................................................................................................10522
3.69 Spark plugs: renewing........................................................................................................................................................................................................................................................................................................................................................................................................................................10523
3.69.1 4-cyl. petrol engine 1.8 ltr. TFSI/2.0 ltr. TFSI (version 1)...........................................................................................................................................................................................................................................................................................................................................................................................10523
3.69.2 4-cyl. petrol engine 1.8 ltr. TFSI/2.0 ltr. TFSI (version 2)...........................................................................................................................................................................................................................................................................................................................................................................................10525
3.69.3 6-cyl. petrol engine 3.0 ltr. TFSI.....................................................................................................................................................................................................................................................................................................................................................................................................................10527
3.69.4 6-cyl. petrol engine 3.2 ltr. FSI......................................................................................................................................................................................................................................................................................................................................................................................................................10530
3.69.5 8-cyl. petrol engine 4.2 ltr. FSI......................................................................................................................................................................................................................................................................................................................................................................................................................10532
3.70 Hydraulic system: checking fluid level.......................................................................................................................................................................................................................................................................................................................................................................................................................10535
3.71 Cooling system: checking anti-freeze and coolant level, and correcting if necessary..........................................................................................................................................................................................................................................................................................................................................................................10536
3.71.1 Checking coolant level and anti-freeze.................................................................................................................................................................................................................................................................................................................................................................................................................10537
3.71.2 Filling up coolant.....................................................................................................................................................................................................................................................................................................................................................................................................................................10539
3.72 Air cleaner: renewing filter element and cleaning housing....................................................................................................................................................................................................................................................................................................................................................................................................10539
3.72.1 4-cyl. petrol engine 1.8 ltr. TFSI/2.0 ltr. TFSI (version 1)...........................................................................................................................................................................................................................................................................................................................................................................................10540
3.72.2 4-cyl. petrol engine 1.8 ltr. TFSI/2.0 ltr. TFSI (version 2)...........................................................................................................................................................................................................................................................................................................................................................................................10541
3.72.3 6-cyl. petrol engine 3.0 ltr. TFSI (version 1).........................................................................................................................................................................................................................................................................................................................................................................................................10542
3.72.4 6-cyl. petrol engine 3.0 ltr. TFSI/3.2 ltr. FSI (version 2)............................................................................................................................................................................................................................................................................................................................................................................................10543
3.72.5 8-cyl. petrol engine 4.2 ltr. FSI (version 1)..........................................................................................................................................................................................................................................................................................................................................................................................................10545
3.72.6 8-cyl. petrol engine 4.2 ltr. FSI (version 2)..........................................................................................................................................................................................................................................................................................................................................................................................................10546
3.72.7 4-cyl. diesel engine 2.0 ltr. TDI (version 1)..........................................................................................................................................................................................................................................................................................................................................................................................................10547
3.72.8 4-cyl. diesel engine 2.0 ltr. TDI (version 2)..........................................................................................................................................................................................................................................................................................................................................................................................................10548
3.72.9 6-cyl. diesel engine 2.7 ltr. TDI/3.0 ltr. TDI.........................................................................................................................................................................................................................................................................................................................................................................................................10549
3.72.10 Cleaning air cleaner housing..........................................................................................................................................................................................................................................................................................................................................................................................................................10551
3.73 Plenum chamber and water drains: checking for dirt...........................................................................................................................................................................................................................................................................................................................................................................................................10551
3.73.1 Checking plenum chamber and water drains for dirt......................................................................................................................................................................................................................................................................................................................................................................................................10551
3.73.2 Cleaning plenum chamber and water drains...............................................................................................................................................................................................................................................................................................................................................................................................................10552
3.74 Snow screen: cleaning........................................................................................................................................................................................................................................................................................................................................................................................................................................10552
3.75 Dust and pollen filter: renewing.............................................................................................................................................................................................................................................................................................................................................................................................................................10553
3.76 Fuel filter: renewing........................................................................................................................................................................................................................................................................................................................................................................................................................................10554
3.77 Fuel tank: adding fuel additive..............................................................................................................................................................................................................................................................................................................................................................................................................................10555
3.78 Reducing agent (AdBlue®): filling up tank completely.........................................................................................................................................................................................................................................................................................................................................................................................................10556
3.78.1 Filling up reducing agent (AdBlue®) using filling device for AdBlue -VAS 6542-.........................................................................................................................................................................................................................................................................................................................................................................10557
3.78.2 Filling up reducing agent (AdBlue®) using AdBlue refuelling system -VAS 6960-..........................................................................................................................................................................................................................................................................................................................................................................10559
3.79 Vehicle doors: removing edge protection......................................................................................................................................................................................................................................................................................................................................................................................................................10560
3.80 Vehicle exterior: checking unprotected areas for dirt, and cleaning if necessary.............................................................................................................................................................................................................................................................................................................................................................................10560
3.81 Vehicle exterior: removing protective film...................................................................................................................................................................................................................................................................................................................................................................................................................10560
3.82 Protective transport film and car cover: checking position and correcting if necessary.......................................................................................................................................................................................................................................................................................................................................................................10561
3.83 Protective transport film: renewing according to manufacturer's instructions.................................................................................................................................................................................................................................................................................................................................................................................10561
3.84 Car cover: renewing according to manufacturer's instructions.................................................................................................................................................................................................................................................................................................................................................................................................10561
3.85 Paintwork, trims, side windows and wiper blades: checking cleanliness........................................................................................................................................................................................................................................................................................................................................................................................10561
3.86 Body: checking vehicle paintwork for damage and corrosion from below and with bonnet, rear lid and doors open................................................................................................................................................................................................................................................................................................................................................10562
3.87 Vehicles parked outdoors: locking............................................................................................................................................................................................................................................................................................................................................................................................................................10562
3.88 Vehicles parked outdoors: covering unprotected vehicles with protective transport film and car cover (not for vehicles with control number 5K0 on data sticker on windscreen)................................................................................................................................................................................................................................................................................10562
3.89 Road test....................................................................................................................................................................................................................................................................................................................................................................................................................................................10562
3.90 Stock vehicles: observing measures specified in Maintenance table for stock vehicles (see “Before handing vehicle over to customer”).........................................................................................................................................................................................................................................................................................................................10563
3.91 Accessories: installing......................................................................................................................................................................................................................................................................................................................................................................................................................................10563
3.92 Checklist "Documentation of cleaning and care routine": checking that list is present........................................................................................................................................................................................................................................................................................................................................................................10564
3.93 Checklist "Documentation of cleaning and care routine": signing and placing in vehicle wallet................................................................................................................................................................................................................................................................................................................................................................10564
3.94 Cleaning and care: checking that required measures have been carried out on time.............................................................................................................................................................................................................................................................................................................................................................................10564
3.95 Stock vehicle care management: deciding and recording date of next check.....................................................................................................................................................................................................................................................................................................................................................................................10564
3.96 Rear final drive: changing gear oil..........................................................................................................................................................................................................................................................................................................................................................................................................................10564
3.97 Rear final drive: changing ATF...............................................................................................................................................................................................................................................................................................................................................................................................................................10564
3.98 Front final drive: changing gear oil.........................................................................................................................................................................................................................................................................................................................................................................................................................10564
3.99 Display instruments: setting time and date...................................................................................................................................................................................................................................................................................................................................................................................................................10565
3.100 Manual gearbox/automatic gearbox: selecting 1st gear/park...................................................................................................................................................................................................................................................................................................................................................................................................10565
3.101 Automatic gearbox (multitronic): changing ATF...............................................................................................................................................................................................................................................................................................................................................................................................................10565
3.102 Dual clutch gearbox (S tronic): changing ATF and renewing exchangeable ATF filter...........................................................................................................................................................................................................................................................................................................................................................................10565
3.103 Dual clutch gearbox (S tronic): changing ATF and renewing exchangeable ATF filter (if fitted)...............................................................................................................................................................................................................................................................................................................................................................10565
3.104 Dual clutch gearbox (S tronic): changing gear oil and renewing oil filter...................................................................................................................................................................................................................................................................................................................................................................................10565
3.105 Interior mirror: calibrating compass........................................................................................................................................................................................................................................................................................................................................................................................................................10565
3.106 Poly V-belt for supercharger with charge air coolers: renewing..............................................................................................................................................................................................................................................................................................................................................................................................10566
3.107 Poly V-belts for ancillaries and all pulleys: renewing......................................................................................................................................................................................................................................................................................................................................................................................................10566
3.108 Instrument cluster: resetting driver information system.....................................................................................................................................................................................................................................................................................................................................................................................................10566
3.109 Toothed belt for camshaft drive: renewing...................................................................................................................................................................................................................................................................................................................................................................................................................10566
3.110 Toothed belt for camshaft drive, and drive sprockets for camshaft, crankshaft and high-pressure pump: renewing..............................................................................................................................................................................................................................................................................................................................................10566
3.111 Toothed belt for camshaft drive and tensioning roller: renewing.............................................................................................................................................................................................................................................................................................................................................................................................10566
3.112 Poly V-belts for ancillaries and pulley for power steering pump: renewing...................................................................................................................................................................................................................................................................................................................................................................................10567
multitronic_0AW__front-wheel_drive........................................................................................................................................................................................................................................................................................................................................................................................................................................10568
00 – Technical data...................................................................................................................................................................................................................................................................................................................................................................................................................................................10572
1 Identification..................................................................................................................................................................................................................................................................................................................................................................................................................................................10572
1.1 Gearbox identification....................................................................................................................................................................................................................................................................................................................................................................................................................................10572
2 Safety precautions..............................................................................................................................................................................................................................................................................................................................................................................................................................................10573
2.1 Safety precautions when working on vehicle................................................................................................................................................................................................................................................................................................................................................................................................................10573
2.2 Safety precautions when working on vehicles with start/stop system........................................................................................................................................................................................................................................................................................................................................................................................10574
2.3 Safety precautions when using testers and measuring instruments during a road test........................................................................................................................................................................................................................................................................................................................................................................10574
2.4 Notes on tow-starting and towing..........................................................................................................................................................................................................................................................................................................................................................................................................................10574
3 Repair instructions.............................................................................................................................................................................................................................................................................................................................................................................................................................................10575
3.1 Rules for cleanliness.....................................................................................................................................................................................................................................................................................................................................................................................................................................10575
3.2 General notes.............................................................................................................................................................................................................................................................................................................................................................................................................................................10575
3.3 General repair instructions...............................................................................................................................................................................................................................................................................................................................................................................................................................10575
3.4 Contact corrosion.........................................................................................................................................................................................................................................................................................................................................................................................................................................10577
4 Technical data..................................................................................................................................................................................................................................................................................................................................................................................................................................................10578
4.1 Capacities................................................................................................................................................................................................................................................................................................................................................................................................................................................10578
37 – Controls, housing................................................................................................................................................................................................................................................................................................................................................................................................................................................10580
1 Selector mechanism..............................................................................................................................................................................................................................................................................................................................................................................................................................................10580
1.1 Exploded view - selector mechanism........................................................................................................................................................................................................................................................................................................................................................................................................................10580
1.2 Exploded view - selector lever handle.....................................................................................................................................................................................................................................................................................................................................................................................................................10582
1.2.1 Exploded view - selector lever handle, vehicles up to model year 2011...............................................................................................................................................................................................................................................................................................................................................................................10582
1.2.2 Exploded view - selector lever handle, vehicles from model year 2012 onwards........................................................................................................................................................................................................................................................................................................................................................................10583
1.3 Exploded view - selector lever cable......................................................................................................................................................................................................................................................................................................................................................................................................................10584
1.4 Checking selector mechanism...............................................................................................................................................................................................................................................................................................................................................................................................................................10585
1.5 Manual release from position P............................................................................................................................................................................................................................................................................................................................................................................................................................10587
1.6 Removing and installing selector mechanism................................................................................................................................................................................................................................................................................................................................................................................................................10588
1.7 Dismantling and assembling selector mechanism.............................................................................................................................................................................................................................................................................................................................................................................................................10591
1.7.1 Removing and installing selector lever lock solenoid -N110-.........................................................................................................................................................................................................................................................................................................................................................................................10591
1.7.2 Removing and installing selector lever sensors control unit -J587- and tiptronic switch -F189-......................................................................................................................................................................................................................................................................................................................................................10593
1.8 Removing and installing selector lever handle.............................................................................................................................................................................................................................................................................................................................................................................................................10595
1.8.1 Removing and installing selector lever handle - vehicles up to model year 2011......................................................................................................................................................................................................................................................................................................................................................................10595
1.8.2 Separating selector lever boot from selector lever handle - vehicles up to model year 2011..........................................................................................................................................................................................................................................................................................................................................................10597
1.8.3 Removing and installing selector lever handle with interlock button (side) - vehicles from model year 2012 onwards..................................................................................................................................................................................................................................................................................................................................10598
1.8.4 Removing and installing selector lever handle with interlock button (front) - vehicles from model year 2012 onwards.................................................................................................................................................................................................................................................................................................................................10600
1.8.5 Moving interlock button on selector lever handle (front) into installation position - vehicles from model year 2012 onwards.........................................................................................................................................................................................................................................................................................................................10602
1.9 Removing and installing selector lever position display -Y26-.............................................................................................................................................................................................................................................................................................................................................................................................10605
1.10 Removing and installing selector lever cable.............................................................................................................................................................................................................................................................................................................................................................................................................10605
1.11 Checking and adjusting selector lever cable..............................................................................................................................................................................................................................................................................................................................................................................................................10610
1.12 Adjusting selector lever cable to basic setting..........................................................................................................................................................................................................................................................................................................................................................................................................10611
1.13 Renewing selector shaft oil seal.........................................................................................................................................................................................................................................................................................................................................................................................................................10614
2 Removing and installing gearbox.................................................................................................................................................................................................................................................................................................................................................................................................................................10615
2.1 Removing gearbox..........................................................................................................................................................................................................................................................................................................................................................................................................................................10615
2.1.1 Removing gearbox, vehicles with 1.8 ltr. and 2.0 ltr. TFSI engine...................................................................................................................................................................................................................................................................................................................................................................................10615
2.1.2 Removing gearbox - vehicles with 3.2 ltr. FSI engine................................................................................................................................................................................................................................................................................................................................................................................................10623
2.1.3 Removing gearbox - vehicles with 2.0 ltr. TDI engine (PR TH3, TM4)..................................................................................................................................................................................................................................................................................................................................................................................10631
2.1.4 Removing gearbox - vehicles with 2.0 ltr. TDI engine (PR TD1).......................................................................................................................................................................................................................................................................................................................................................................................10640
2.1.5 Removing gearbox - vehicles with 2.7 ltr. TDI engine................................................................................................................................................................................................................................................................................................................................................................................................10647
2.1.6 Removing gearbox, vehicles with 3.0 ltr. TDI engine.................................................................................................................................................................................................................................................................................................................................................................................................10654
2.2 Installing gearbox........................................................................................................................................................................................................................................................................................................................................................................................................................................10662
2.2.1 Installing gearbox, vehicles with 1.8 ltr. and 2.0 ltr. TFSI engine.................................................................................................................................................................................................................................................................................................................................................................................10662
2.2.2 Installing gearbox, vehicles with 3.2 ltr. FSI engine...............................................................................................................................................................................................................................................................................................................................................................................................10668
2.2.3 Installing gearbox - vehicles with 2.0 ltr. TDI engine..............................................................................................................................................................................................................................................................................................................................................................................................10673
2.2.4 Installing gearbox, vehicles with 2.7 ltr./3.0 ltr. TDI engine......................................................................................................................................................................................................................................................................................................................................................................................10679
2.3 Tightening torques for gearbox............................................................................................................................................................................................................................................................................................................................................................................................................................10685
3 Assembly mountings..............................................................................................................................................................................................................................................................................................................................................................................................................................................10690
3.1 Exploded view - assembly mountings........................................................................................................................................................................................................................................................................................................................................................................................................................10690
3.2 Removing and installing tunnel cross member...............................................................................................................................................................................................................................................................................................................................................................................................................10690
3.3 Removing and installing gearbox support with gearbox mounting.............................................................................................................................................................................................................................................................................................................................................................................................10692
4 Transporting gearbox............................................................................................................................................................................................................................................................................................................................................................................................................................................10694
5 Securing to engine and gearbox support..........................................................................................................................................................................................................................................................................................................................................................................................................................10695
6 ATF.............................................................................................................................................................................................................................................................................................................................................................................................................................................................10696
6.1 Exploded view - ATF drain and inspection plugs in gearbox.................................................................................................................................................................................................................................................................................................................................................................................................10696
6.2 Checking ATF level........................................................................................................................................................................................................................................................................................................................................................................................................................................10696
6.3 Draining and filling ATF..................................................................................................................................................................................................................................................................................................................................................................................................................................10703
7 ATF circuit.....................................................................................................................................................................................................................................................................................................................................................................................................................................................10710
7.1 Exploded view - ATF circuit...............................................................................................................................................................................................................................................................................................................................................................................................................................10710
7.2 Removing and installing ATF filter........................................................................................................................................................................................................................................................................................................................................................................................................................10712
7.3 Cleaning ATF lines........................................................................................................................................................................................................................................................................................................................................................................................................................................10714
7.4 Removing and installing ATF lines.........................................................................................................................................................................................................................................................................................................................................................................................................................10715
7.4.1 Removing and installing ATF lines, vehicles with 1.8 ltr. and 2.0 ltr. TFSI engine..................................................................................................................................................................................................................................................................................................................................................................10715
7.4.2 Removing and installing ATF lines, vehicles with 2.0 ltr. TDI engine or 6-cylinder engine...........................................................................................................................................................................................................................................................................................................................................................10716
38 – Gears, control...................................................................................................................................................................................................................................................................................................................................................................................................................................................10718
1 Dismantling and assembling gearbox..............................................................................................................................................................................................................................................................................................................................................................................................................................10718
1.1 Exploded view - dual-mass flywheel........................................................................................................................................................................................................................................................................................................................................................................................................................10718
1.2 Exploded view - end cover.................................................................................................................................................................................................................................................................................................................................................................................................................................10718
1.3 Removing and installing dual-mass flywheel................................................................................................................................................................................................................................................................................................................................................................................................................10719
1.4 Removing and installing end cover.........................................................................................................................................................................................................................................................................................................................................................................................................................10719
39 – Final drive - differential.......................................................................................................................................................................................................................................................................................................................................................................................................................................10723
1 Final drive.....................................................................................................................................................................................................................................................................................................................................................................................................................................................10723
1.1 Exploded view - final drive...............................................................................................................................................................................................................................................................................................................................................................................................................................10723
2 Gear oil........................................................................................................................................................................................................................................................................................................................................................................................................................................................10725
2.1 Checking gear oil level...................................................................................................................................................................................................................................................................................................................................................................................................................................10725
2.2 Draining and filling gear oil.............................................................................................................................................................................................................................................................................................................................................................................................................................10728
3 Oil seals.......................................................................................................................................................................................................................................................................................................................................................................................................................................................10731
3.1 Renewing oil seal (left-side).............................................................................................................................................................................................................................................................................................................................................................................................................................10731
3.2 Renewing oil seal (right-side)............................................................................................................................................................................................................................................................................................................................................................................................................................10731
3.3 Renewing oil seal for input shaft.........................................................................................................................................................................................................................................................................................................................................................................................................................10731
4 Differential....................................................................................................................................................................................................................................................................................................................................................................................................................................................10732
4.1 Removing and installing flange shaft (left-side)..........................................................................................................................................................................................................................................................................................................................................................................................................10732
4.2 Removing and installing flange shaft (right-side).........................................................................................................................................................................................................................................................................................................................................................................................................10732
5 Gearbox control system..........................................................................................................................................................................................................................................................................................................................................................................................................................................10735
5.1 Overview of fitting locations - gearbox control system....................................................................................................................................................................................................................................................................................................................................................................................................10735
5.2 Removing and installing gearbox control unit..............................................................................................................................................................................................................................................................................................................................................................................................................10737
5.3 Removing and installing hydraulic control unit............................................................................................................................................................................................................................................................................................................................................................................................................10738
Rear_final_drive_0BC__0BD__0BE__0BF.......................................................................................................................................................................................................................................................................................................................................................................................................................................10739
00 – Technical data...................................................................................................................................................................................................................................................................................................................................................................................................................................................10743
1 Identification..................................................................................................................................................................................................................................................................................................................................................................................................................................................10743
1.1 Identification of final drive.............................................................................................................................................................................................................................................................................................................................................................................................................................10743
1.1.1 Identification of final drive 0BC...................................................................................................................................................................................................................................................................................................................................................................................................................10743
1.1.2 Identification of final drive 0BD...................................................................................................................................................................................................................................................................................................................................................................................................................10744
1.1.3 Identification of final drive 0BE, 0BF..............................................................................................................................................................................................................................................................................................................................................................................................................10745
2 Technical data..................................................................................................................................................................................................................................................................................................................................................................................................................................................10747
2.1 Allocation of gearbox to engine...........................................................................................................................................................................................................................................................................................................................................................................................................................10747
2.2 Capacities................................................................................................................................................................................................................................................................................................................................................................................................................................................10747
2.2.1 Capacities - rear final drive 0BC...................................................................................................................................................................................................................................................................................................................................................................................................................10747
2.2.2 Capacities - rear final drive 0BD...................................................................................................................................................................................................................................................................................................................................................................................................................10747
2.2.3 Capacities - rear final drive 0BF...................................................................................................................................................................................................................................................................................................................................................................................................................10747
2.2.4 Capacities - rear final drive 0BE...................................................................................................................................................................................................................................................................................................................................................................................................................10748
3 Transmission layout.............................................................................................................................................................................................................................................................................................................................................................................................................................................10750
4 Electrical components...........................................................................................................................................................................................................................................................................................................................................................................................................................................10751
4.1 Overview of fitting locations - electrical components.....................................................................................................................................................................................................................................................................................................................................................................................................10751
5 Safety precautions..............................................................................................................................................................................................................................................................................................................................................................................................................................................10752
5.1 General safety precautions................................................................................................................................................................................................................................................................................................................................................................................................................................10752
5.2 Safety precautions when working on high-voltage vehicles..................................................................................................................................................................................................................................................................................................................................................................................................10753
5.2.1 Safety precautions for de-energising high-voltage system............................................................................................................................................................................................................................................................................................................................................................................................10753
5.2.2 Safety precautions for re-energising high-voltage system............................................................................................................................................................................................................................................................................................................................................................................................10754
6 Repair instructions.............................................................................................................................................................................................................................................................................................................................................................................................................................................10756
6.1 General repair instructions...............................................................................................................................................................................................................................................................................................................................................................................................................................10756
6.2 Safety precautions and testing............................................................................................................................................................................................................................................................................................................................................................................................................................10756
6.3 Jacking mode (vehicles with air suspension)...............................................................................................................................................................................................................................................................................................................................................................................................................10758
6.4 Special tools.............................................................................................................................................................................................................................................................................................................................................................................................................................................10758
6.5 Components................................................................................................................................................................................................................................................................................................................................................................................................................................................10758
39 – Final drive - rear differential..................................................................................................................................................................................................................................................................................................................................................................................................................................10761
1 Propshaft.......................................................................................................................................................................................................................................................................................................................................................................................................................................................10761
1.1 Exploded view - propshaft.................................................................................................................................................................................................................................................................................................................................................................................................................................10761
1.1.1 Exploded view - propshaft with splines on gearbox end...............................................................................................................................................................................................................................................................................................................................................................................................10761
1.1.2 Exploded view - propshaft with bolted connection at gearbox end.....................................................................................................................................................................................................................................................................................................................................................................................10764
1.2 Removing and installing propshaft.........................................................................................................................................................................................................................................................................................................................................................................................................................10766
1.2.1 Removing and installing propshaft with splines on gearbox end.......................................................................................................................................................................................................................................................................................................................................................................................10766
1.2.2 Removing and installing propshaft with bolted connection at gearbox end.............................................................................................................................................................................................................................................................................................................................................................................10773
1.3 Detaching and attaching propshaft at gearbox or at rear final drive.......................................................................................................................................................................................................................................................................................................................................................................................10779
1.3.1 Detaching and attaching propshaft at gearbox with bolted connection at gearbox end..................................................................................................................................................................................................................................................................................................................................................................10779
1.3.2 Detaching and attaching propshaft at rear final drive...............................................................................................................................................................................................................................................................................................................................................................................................10781
1.4 Renewing protective boot..................................................................................................................................................................................................................................................................................................................................................................................................................................10783
1.4.1 Renewing protective boot for propshaft with splines on gearbox end..................................................................................................................................................................................................................................................................................................................................................................................10783
2 Final drive.....................................................................................................................................................................................................................................................................................................................................................................................................................................................10787
2.1 Exploded view - final drive...............................................................................................................................................................................................................................................................................................................................................................................................................................10787
2.1.1 Exploded view - final drive 0BC, 0BD................................................................................................................................................................................................................................................................................................................................................................................................................10787
2.1.2 Exploded view - final drive 0BE, 0BF................................................................................................................................................................................................................................................................................................................................................................................................................10789
2.2 Removing and installing final drive.......................................................................................................................................................................................................................................................................................................................................................................................................................10790
2.2.1 Removing and installing final drive 0BC for Audi A4, A5, A6, A7, Q5 (not Q5 hybrid).................................................................................................................................................................................................................................................................................................................................................................10790
2.2.2 Removing and installing final drive 0BC for Audi Q5 hybrid..........................................................................................................................................................................................................................................................................................................................................................................................10797
2.2.3 Removing and installing final drive 0BC for Audi A8.................................................................................................................................................................................................................................................................................................................................................................................................10805
2.2.4 Removing and installing final drive 0BD for Audi A4, A5, Q5.........................................................................................................................................................................................................................................................................................................................................................................................10812
2.2.5 Removing and installing final drive 0BF for Audi A4, A5, A6, A7, Q5.................................................................................................................................................................................................................................................................................................................................................................................10818
2.2.6 Removing and installing final drive 0BF for Audi RS 4, RS 5.........................................................................................................................................................................................................................................................................................................................................................................................10824
2.2.7 Removing and installing final drive 0BE, 0BF for Audi A8............................................................................................................................................................................................................................................................................................................................................................................................10827
2.2.8 Additional work required after renewing final drive 0BE, 0BF........................................................................................................................................................................................................................................................................................................................................................................................10830
3 Dismantling and assembling final drive..........................................................................................................................................................................................................................................................................................................................................................................................................................10832
3.1 Exploded view - dismantling and assembling final drive....................................................................................................................................................................................................................................................................................................................................................................................................10832
3.1.1 Exploded view - dismantling and assembling final drive 0BE, 0BF.....................................................................................................................................................................................................................................................................................................................................................................................10832
3.2 Removing and installing hydraulic control unit............................................................................................................................................................................................................................................................................................................................................................................................................10835
3.2.1 Removing and installing hydraulic control unit, 0BE, 0BF............................................................................................................................................................................................................................................................................................................................................................................................10835
3.3 Dismantling and assembling hydraulic control unit.........................................................................................................................................................................................................................................................................................................................................................................................................10838
3.3.1 Dismantling and assembling hydraulic control unit, 0BE, 0BF.........................................................................................................................................................................................................................................................................................................................................................................................10838
3.4 Removing and installing all-wheel drive pump -V415-.......................................................................................................................................................................................................................................................................................................................................................................................................10841
3.4.1 Removing and installing all-wheel drive pump -V415-, 0BE, 0BF.......................................................................................................................................................................................................................................................................................................................................................................................10841
3.5 Removing and installing oil pressure and oil temperature sender -G437- or oil pressure and oil temperature sender 2 -G640-................................................................................................................................................................................................................................................................................................................................10843
3.5.1 Removing and installing oil pressure and oil temperature sender -G437- or oil pressure and oil temperature sender 2 -G64�-, 0BE, 0BF................................................................................................................................................................................................................................................................................................................10843
3.6 Removing and installing clutch valve for all-wheel drive -N445- or clutch valve 2 for all-wheel drive -N446-..............................................................................................................................................................................................................................................................................................................................................10846
3.6.1 Removing and installing clutch valve for all-wheel drive -N445- or clutch valve 2 for all-wheel drive -N446-, 0BE, 0BF..............................................................................................................................................................................................................................................................................................................................10846
3.7 Checking torque distribution..............................................................................................................................................................................................................................................................................................................................................................................................................................10848
3.7.1 Checking torque distribution, 0BE, 0BF..............................................................................................................................................................................................................................................................................................................................................................................................................10848
4 Gear oil........................................................................................................................................................................................................................................................................................................................................................................................................................................................10849
4.1 Overview - drain and inspection plugs.....................................................................................................................................................................................................................................................................................................................................................................................................................10849
4.2 Checking gear oil level...................................................................................................................................................................................................................................................................................................................................................................................................................................10849
4.2.1 Checking gear oil level, 0BC........................................................................................................................................................................................................................................................................................................................................................................................................................10849
4.2.2 Checking gear oil level, 0BD........................................................................................................................................................................................................................................................................................................................................................................................................................10850
4.2.3 Checking gear oil level, 0BE, 0BF...................................................................................................................................................................................................................................................................................................................................................................................................................10850
4.3 Draining and filling gear oil.............................................................................................................................................................................................................................................................................................................................................................................................................................10851
4.3.1 Draining gear oil, 0BE, 0BF.........................................................................................................................................................................................................................................................................................................................................................................................................................10851
4.3.2 Filling up gear oil, 0BE............................................................................................................................................................................................................................................................................................................................................................................................................................10853
4.3.3 Filling up gear oil, 0BF............................................................................................................................................................................................................................................................................................................................................................................................................................10855
5 ATF.............................................................................................................................................................................................................................................................................................................................................................................................................................................................10858
5.1 Overview - drain and inspection plugs.....................................................................................................................................................................................................................................................................................................................................................................................................................10858
5.1.1 Overview - drain and inspection plugs, 0BE..........................................................................................................................................................................................................................................................................................................................................................................................................10858
5.1.2 Overview - drain and inspection plugs, 0BF..........................................................................................................................................................................................................................................................................................................................................................................................................10858
5.2 Checking ATF level........................................................................................................................................................................................................................................................................................................................................................................................................................................10858
5.2.1 Checking ATF level, 0BE, 0BF........................................................................................................................................................................................................................................................................................................................................................................................................................10858
5.3 Draining and filling ATF..................................................................................................................................................................................................................................................................................................................................................................................................................................10859
5.3.1 Draining ATF, 0BE...................................................................................................................................................................................................................................................................................................................................................................................................................................10859
5.3.2 Draining ATF, 0BF...................................................................................................................................................................................................................................................................................................................................................................................................................................10859
5.3.3 Filling up ATF, 0BE, 0BF............................................................................................................................................................................................................................................................................................................................................................................................................................10860
6 Oil seals.......................................................................................................................................................................................................................................................................................................................................................................................................................................................10864
6.1 Overview of fitting locations - oil seals.................................................................................................................................................................................................................................................................................................................................................................................................................10864
6.1.1 Overview of fitting locations - oil seals, 0BC, 0BD.................................................................................................................................................................................................................................................................................................................................................................................................10864
6.1.2 Overview of fitting locations - oil seals, 0BE, 0BF.................................................................................................................................................................................................................................................................................................................................................................................................10865
6.2 Renewing oil seal (left-side).............................................................................................................................................................................................................................................................................................................................................................................................................................10865
6.2.1 Renewing oil seal (left-side), 0BC..................................................................................................................................................................................................................................................................................................................................................................................................................10865
6.2.2 Renewing oil seal (left-side), 0BD..................................................................................................................................................................................................................................................................................................................................................................................................................10868
6.2.3 Renewing oil seal (left-side), 0BE, 0BF.............................................................................................................................................................................................................................................................................................................................................................................................................10870
6.3 Renewing oil seal (right-side)............................................................................................................................................................................................................................................................................................................................................................................................................................10872
6.4 Renewing input shaft oil seal.............................................................................................................................................................................................................................................................................................................................................................................................................................10872
6.4.1 Renewing input shaft oil seal, 0BC..................................................................................................................................................................................................................................................................................................................................................................................................................10872
6.4.2 Renewing input shaft oil seal, 0BD..................................................................................................................................................................................................................................................................................................................................................................................................................10879
6.4.3 Renewing input shaft oil seal, 0BE..................................................................................................................................................................................................................................................................................................................................................................................................................10884
6.4.4 Renewing input shaft oil seal, 0BF..................................................................................................................................................................................................................................................................................................................................................................................................................10889
6.5 Renewing protective ring on flange shaft..................................................................................................................................................................................................................................................................................................................................................................................................................10896
6.5.1 Renewing protective ring on flange shaft, 0BC.......................................................................................................................................................................................................................................................................................................................................................................................................10896
6.5.2 Renewing protective ring on flange shaft, 0BD.......................................................................................................................................................................................................................................................................................................................................................................................................10898
6.5.3 Renewing protective ring on flange shaft, 0BE, 0BF..................................................................................................................................................................................................................................................................................................................................................................................................10900
6.6 Renewing protective ring on input shaft flange............................................................................................................................................................................................................................................................................................................................................................................................................10903
6.6.1 Renewing protective ring on input shaft flange, 0BC.................................................................................................................................................................................................................................................................................................................................................................................................10903
6.6.2 Renewing protective ring on input shaft flange, 0BD.................................................................................................................................................................................................................................................................................................................................................................................................10905
6.6.3 Renewing protective ring on input shaft flange, 0BE, 0BF............................................................................................................................................................................................................................................................................................................................................................................................10906
7 Renewing propshaft flange, 0BD..................................................................................................................................................................................................................................................................................................................................................................................................................................10909
8 Gearbox control system..........................................................................................................................................................................................................................................................................................................................................................................................................................................10913
8.1 Overview of fitting locations - gearbox control system....................................................................................................................................................................................................................................................................................................................................................................................................10913
8.2 Removing and installing all-wheel drive control unit -J492-...............................................................................................................................................................................................................................................................................................................................................................................................10914
8.3 Additional work required after renewing all-wheel drive control unit -J492-...............................................................................................................................................................................................................................................................................................................................................................................10915
Rear_final_drive_0BD......................................................................................................................................................................................................................................................................................................................................................................................................................................................10916
00 – Technical data...................................................................................................................................................................................................................................................................................................................................................................................................................................................10920
1 Rear final drive identification.................................................................................................................................................................................................................................................................................................................................................................................................................................10920
2 Code letters, allocation, transmission ratios, capacities.......................................................................................................................................................................................................................................................................................................................................................................................................10922
2.1 Audi A4 2008 ► - Code letters, allocation, transmission ratios, capacities................................................................................................................................................................................................................................................................................................................................................................................10922
2.2 Audi A5 Coupé 2008 ► - Code letters, allocation, transmission ratios, capacities..........................................................................................................................................................................................................................................................................................................................................................................10922
2.3 Audi A5 Cabriolet 2009 ► - Code letters, allocation, transmission ratios, capacities......................................................................................................................................................................................................................................................................................................................................................................10922
2.4 Audi Q5 2008 ► - Code letters, allocation, transmission ratios, capacities................................................................................................................................................................................................................................................................................................................................................................................10923
3 Transmission layout.............................................................................................................................................................................................................................................................................................................................................................................................................................................10924
4 General repair instructions.....................................................................................................................................................................................................................................................................................................................................................................................................................................10925
4.1 Jacking mode (vehicles with air suspension)...............................................................................................................................................................................................................................................................................................................................................................................................................10925
4.2 Special tools.............................................................................................................................................................................................................................................................................................................................................................................................................................................10925
4.3 Components................................................................................................................................................................................................................................................................................................................................................................................................................................................10925
39 – Final drive - rear differential..................................................................................................................................................................................................................................................................................................................................................................................................................................10927
1 Exploded view - propshaft with bolted connection at gearbox end.................................................................................................................................................................................................................................................................................................................................................................................................10927
1.1 Removing and installing propshaft with bolted connection at gearbox end...................................................................................................................................................................................................................................................................................................................................................................................10929
1.2 Detaching and attaching propshaft at gearbox..............................................................................................................................................................................................................................................................................................................................................................................................................10934
1.3 Detaching and attaching propshaft at rear final drive.....................................................................................................................................................................................................................................................................................................................................................................................................10936
2 Exploded view - propshaft with splines on gearbox end...........................................................................................................................................................................................................................................................................................................................................................................................................10939
2.1 Removing and installing propshaft with splines on gearbox end.............................................................................................................................................................................................................................................................................................................................................................................................10941
2.2 Renewing protective boot for propshaft with splines on gearbox end........................................................................................................................................................................................................................................................................................................................................................................................10947
3 Checking gear oil in rear final drive...........................................................................................................................................................................................................................................................................................................................................................................................................................10951
4 Removing and installing rear final drive........................................................................................................................................................................................................................................................................................................................................................................................................................10952
4.1 Exploded view - rear final drive..........................................................................................................................................................................................................................................................................................................................................................................................................................10952
4.2 Removing and installing rear final drive..................................................................................................................................................................................................................................................................................................................................................................................................................10953
5 Renewing oil seals for flange shafts (rear final drive removed).................................................................................................................................................................................................................................................................................................................................................................................................10961
5.1 Renewing oil seal for flange shaft (right-side)...........................................................................................................................................................................................................................................................................................................................................................................................................10962
5.2 Renewing oil seal for flange shaft (left-side)............................................................................................................................................................................................................................................................................................................................................................................................................10963
5.3 Renewing protective ring on flange shaft..................................................................................................................................................................................................................................................................................................................................................................................................................10965
6 Renewing oil seal for flange for propshaft (rear final drive removed)...........................................................................................................................................................................................................................................................................................................................................................................................10967
6.1 Renewing oil seal and flange for propshaft (rear final drive removed).....................................................................................................................................................................................................................................................................................................................................................................................10972
6.2 Renewing protective ring on propshaft flange..............................................................................................................................................................................................................................................................................................................................................................................................................10976
Rear_final_drive_0BF_and_0BE_-_sport_differential.........................................................................................................................................................................................................................................................................................................................................................................................................................10978
00 – Technical data...................................................................................................................................................................................................................................................................................................................................................................................................................................................10982
1 Identification of rear final drive units 0BF and 0BE............................................................................................................................................................................................................................................................................................................................................................................................................10982
2 Code letters, allocation, transmission ratios, capacities.......................................................................................................................................................................................................................................................................................................................................................................................................10984
2.1 Audi A4 2008 ► - Code letters, allocation, transmission ratios, capacities................................................................................................................................................................................................................................................................................................................................................................................10984
2.2 Audi A5 Coupé 2008 ► - Code letters, allocation, transmission ratios, capacities..........................................................................................................................................................................................................................................................................................................................................................................10986
2.3 Audi A5 Sportback 2010 ► - Code letters, allocation, transmission ratios, capacities......................................................................................................................................................................................................................................................................................................................................................................10988
2.4 Audi A5 Cabriolet 2009 ► - Code letters, allocation, transmission ratios, capacities......................................................................................................................................................................................................................................................................................................................................................................10989
2.5 Audi A6 2011 ► - Code letters, allocations, transmission ratios, capacities...............................................................................................................................................................................................................................................................................................................................................................................10989
2.6 Audi A7 2011 ► - Code letters, allocation, transmission ratios, capacities................................................................................................................................................................................................................................................................................................................................................................................10990
2.7 Audi A8 2010 ► - Code letters, allocation, transmission ratios, capacities................................................................................................................................................................................................................................................................................................................................................................................10991
3 Transmission layout.............................................................................................................................................................................................................................................................................................................................................................................................................................................10993
4 General repair instructions.....................................................................................................................................................................................................................................................................................................................................................................................................................................10994
4.1 Safety precautions and testing measures...................................................................................................................................................................................................................................................................................................................................................................................................................10994
4.2 Jacking mode (vehicles with air suspension)...............................................................................................................................................................................................................................................................................................................................................................................................................10996
4.3 Special tools.............................................................................................................................................................................................................................................................................................................................................................................................................................................10996
4.4 Components................................................................................................................................................................................................................................................................................................................................................................................................................................................10996
39 – Final drive - rear differential..................................................................................................................................................................................................................................................................................................................................................................................................................................10999
1 Exploded view - propshaft with bolted connection at gearbox end (Audi A4 and A5)................................................................................................................................................................................................................................................................................................................................................................................10999
1.1 Removing and installing propshaft with bolted connection at gearbox end...................................................................................................................................................................................................................................................................................................................................................................................11001
1.2 Detaching and attaching propshaft at gearbox (version with bolted connection at gearbox end)..............................................................................................................................................................................................................................................................................................................................................................11006
2 Detaching and attaching propshaft at rear final drive...........................................................................................................................................................................................................................................................................................................................................................................................................11009
3 Exploded view - propshaft with splines on gearbox end...........................................................................................................................................................................................................................................................................................................................................................................................................11012
3.1 Removing and installing propshaft with splines on gearbox end.............................................................................................................................................................................................................................................................................................................................................................................................11014
4 Electrical/electronic components and fitting locations..........................................................................................................................................................................................................................................................................................................................................................................................................11021
4.1 Removing and installing four-wheel drive control unit -J492-..............................................................................................................................................................................................................................................................................................................................................................................................11023
4.2 Additional work required after renewing four-wheel drive control unit -J492-..............................................................................................................................................................................................................................................................................................................................................................................11024
5 Exploded view - rear final drive................................................................................................................................................................................................................................................................................................................................................................................................................................11025
6 Dismantling and assembling rear final drive.....................................................................................................................................................................................................................................................................................................................................................................................................................11028
6.1 Removing and installing hydraulic control unit............................................................................................................................................................................................................................................................................................................................................................................................................11028
6.2 Dismantling and assembling hydraulic control unit.........................................................................................................................................................................................................................................................................................................................................................................................................11031
6.3 Removing and installing four-wheel drive pump -V415-......................................................................................................................................................................................................................................................................................................................................................................................................11034
6.4 Removing and installing oil pressure and oil temperature sender -G437- or oil pressure and oil temperature sender 2 -G640-................................................................................................................................................................................................................................................................................................................................11035
6.5 Removing and installing clutch for four-wheel drive -N445- or clutch valve 2 for four-wheel drive -N446-..................................................................................................................................................................................................................................................................................................................................................11038
7 Checking torque distribution....................................................................................................................................................................................................................................................................................................................................................................................................................................11041
8 Removing and installing rear final drive........................................................................................................................................................................................................................................................................................................................................................................................................................11042
8.1 Exploded view - rear final drive (Audi A4, A5 Coupé/Sportback/Cabriolet, A6, A7)..........................................................................................................................................................................................................................................................................................................................................................................11042
8.2 Removing and installing rear final drive (Audi A4, A5 Coupé/Sportback/Cabriolet, A6, A7)..................................................................................................................................................................................................................................................................................................................................................................11043
8.3 Exploded view - rear final drive (RS 5)...................................................................................................................................................................................................................................................................................................................................................................................................................11049
8.4 Removing and installing rear final drive (RS 5)...........................................................................................................................................................................................................................................................................................................................................................................................................11049
8.5 Exploded view - rear final drive (Audi A8)................................................................................................................................................................................................................................................................................................................................................................................................................11053
8.6 Removing and installing rear final drive (Audi A8)........................................................................................................................................................................................................................................................................................................................................................................................................11053
8.7 Additional work required after renewing rear final drive..................................................................................................................................................................................................................................................................................................................................................................................................11056
9 Gear oil and ATF in rear final drive............................................................................................................................................................................................................................................................................................................................................................................................................................11058
9.1 Overview of drain plugs and inspection plugs for ATF and gear oil (rear final drive 0BF and 0BE)..........................................................................................................................................................................................................................................................................................................................................................11058
9.2 Checking gear oil level in rear final drive 0BF and 0BE...................................................................................................................................................................................................................................................................................................................................................................................................11059
9.3 Draining gear oil from rear final drive 0BF and 0BE.......................................................................................................................................................................................................................................................................................................................................................................................................11060
9.4 Filling up gear oil in rear final drive 0BF...............................................................................................................................................................................................................................................................................................................................................................................................................11061
9.5 Filling up gear oil in rear final drive 0BE...............................................................................................................................................................................................................................................................................................................................................................................................................11063
9.6 Checking ATF level in rear final drive 0BF and 0BE........................................................................................................................................................................................................................................................................................................................................................................................................11065
9.7 Draining ATF from rear final drive 0BF and 0BE............................................................................................................................................................................................................................................................................................................................................................................................................11066
9.8 Filling up ATF in rear final drive 0BF and 0BE............................................................................................................................................................................................................................................................................................................................................................................................................11067
10 Renewing oil seals for flange shafts (rear final drive removed)................................................................................................................................................................................................................................................................................................................................................................................................11070
10.1 Renewing protective ring on flange shaft.................................................................................................................................................................................................................................................................................................................................................................................................................11072
11 Renewing oil seal for propshaft flange.........................................................................................................................................................................................................................................................................................................................................................................................................................11074
11.1 Rear final drive 0BF - renewing oil seal for propshaft flange............................................................................................................................................................................................................................................................................................................................................................................................11074
11.2 Rear final drive 0BE - renewing oil seal for propshaft flange............................................................................................................................................................................................................................................................................................................................................................................................11080
11.3 Renewing protective ring on propshaft flange.............................................................................................................................................................................................................................................................................................................................................................................................................11087
Running_gear__axles__steering.............................................................................................................................................................................................................................................................................................................................................................................................................................................11089
00 – Technical data...................................................................................................................................................................................................................................................................................................................................................................................................................................................11095
1 General notes...................................................................................................................................................................................................................................................................................................................................................................................................................................................11095
1.1 General notes on Tyre Pressure Loss Indicator (TPLI+).....................................................................................................................................................................................................................................................................................................................................................................................................11095
1.2 General notes on Tyre Pressure Monitoring System (TPMS)...................................................................................................................................................................................................................................................................................................................................................................................................11096
1.3 General notes on dynamic steering.........................................................................................................................................................................................................................................................................................................................................................................................................................11097
1.4 General notes on drive shaft..............................................................................................................................................................................................................................................................................................................................................................................................................................11098
1.5 General notes on adaptive cruise control..................................................................................................................................................................................................................................................................................................................................................................................................................11099
1.6 General notes on lane departure warning function..........................................................................................................................................................................................................................................................................................................................................................................................................11100
2 Repair notes....................................................................................................................................................................................................................................................................................................................................................................................................................................................11102
2.1 Leaks at shock absorbers..................................................................................................................................................................................................................................................................................................................................................................................................................................11102
2.2 Noises from shock absorbers...............................................................................................................................................................................................................................................................................................................................................................................................................................11102
2.3 Checking shock absorbers when removed.....................................................................................................................................................................................................................................................................................................................................................................................................................11103
2.4 Checking shock absorbers on shock tester..................................................................................................................................................................................................................................................................................................................................................................................................................11103
2.5 General notes.............................................................................................................................................................................................................................................................................................................................................................................................................................................11107
2.5.1 General notes on front axle.........................................................................................................................................................................................................................................................................................................................................................................................................................11107
2.5.2 General notes on rear axle..........................................................................................................................................................................................................................................................................................................................................................................................................................11108
2.5.3 General notes on steering...........................................................................................................................................................................................................................................................................................................................................................................................................................11109
2.6 Contact corrosion.........................................................................................................................................................................................................................................................................................................................................................................................................................................11110
2.7 Repairing damaged threads in longitudinal member (subframe to body).......................................................................................................................................................................................................................................................................................................................................................................................11110
2.8 Lifting suspension to unladen position (vehicles with coil springs).......................................................................................................................................................................................................................................................................................................................................................................................11111
2.8.1 Lifting suspension to unladen position on vehicles with coil springs (front axle)...................................................................................................................................................................................................................................................................................................................................................................11111
2.8.2 Lifting suspension to unladen position on vehicles with coil springs (rear axle)....................................................................................................................................................................................................................................................................................................................................................................11112
2.9 Steering rack.............................................................................................................................................................................................................................................................................................................................................................................................................................................11114
2.10 Gaskets and seals........................................................................................................................................................................................................................................................................................................................................................................................................................................11114
2.11 Bolts and nuts...........................................................................................................................................................................................................................................................................................................................................................................................................................................11115
2.12 Electrical components....................................................................................................................................................................................................................................................................................................................................................................................................................................11115
3 Technical data..................................................................................................................................................................................................................................................................................................................................................................................................................................................11116
3.1 Running gear..............................................................................................................................................................................................................................................................................................................................................................................................................................................11116
3.1.1 A4 running gear.....................................................................................................................................................................................................................................................................................................................................................................................................................................11116
3.1.2 A5 running gear.....................................................................................................................................................................................................................................................................................................................................................................................................................................11117
3.2 Steering..................................................................................................................................................................................................................................................................................................................................................................................................................................................11120
4 Disposal........................................................................................................................................................................................................................................................................................................................................................................................................................................................11121
4.1 Releasing gas and draining front gas-filled shock absorbers...............................................................................................................................................................................................................................................................................................................................................................................................11121
4.2 Releasing gas and draining gas-filled shock absorbers (rear)..............................................................................................................................................................................................................................................................................................................................................................................................11122
4.3 Draining power steering rack..............................................................................................................................................................................................................................................................................................................................................................................................................................11123
40 – Front suspension.................................................................................................................................................................................................................................................................................................................................................................................................................................................11124
1 Front axle......................................................................................................................................................................................................................................................................................................................................................................................................................................................11124
1.1 Overview - front axle.....................................................................................................................................................................................................................................................................................................................................................................................................................................11124
2 Subframe........................................................................................................................................................................................................................................................................................................................................................................................................................................................11125
2.1 Exploded view - subframe..................................................................................................................................................................................................................................................................................................................................................................................................................................11125
2.1.1 Exploded view - subframe, A5 up to August 2007......................................................................................................................................................................................................................................................................................................................................................................................................11125
2.1.2 Exploded view - subframe, A5 from September 2007 onwards............................................................................................................................................................................................................................................................................................................................................................................................11127
2.1.3 Exploded view - subframe, A4........................................................................................................................................................................................................................................................................................................................................................................................................................11130
2.2 Removing and installing subframe without steering rack....................................................................................................................................................................................................................................................................................................................................................................................................11132
2.3 Removing and installing subframe cross brace..............................................................................................................................................................................................................................................................................................................................................................................................................11139
2.3.1 Removing and installing subframe cross brace (A4, A5 Coupé, A5 Sportback)...........................................................................................................................................................................................................................................................................................................................................................................11139
2.3.2 Removing and installing subframe cross brace (A5 Cabriolet).........................................................................................................................................................................................................................................................................................................................................................................................11140
2.4 Removing and installing subframe shield...................................................................................................................................................................................................................................................................................................................................................................................................................11142
2.5 Removing and installing diagonal strut....................................................................................................................................................................................................................................................................................................................................................................................................................11143
2.6 Removing and installing anti-roll bar.....................................................................................................................................................................................................................................................................................................................................................................................................................11144
2.7 Removing and installing coupling rod......................................................................................................................................................................................................................................................................................................................................................................................................................11146
3 Suspension strut, upper links...................................................................................................................................................................................................................................................................................................................................................................................................................................11148
3.1 Exploded view - suspension strut, upper links.............................................................................................................................................................................................................................................................................................................................................................................................................11148
3.2 Removing and installing suspension strut..................................................................................................................................................................................................................................................................................................................................................................................................................11150
3.3 Servicing suspension strut................................................................................................................................................................................................................................................................................................................................................................................................................................11155
3.4 Removing and installing upper links.......................................................................................................................................................................................................................................................................................................................................................................................................................11161
3.5 Renewing bush for upper link..............................................................................................................................................................................................................................................................................................................................................................................................................................11163
3.6 Removing and installing shock absorber fork...............................................................................................................................................................................................................................................................................................................................................................................................................11164
3.7 Removing and installing body brace........................................................................................................................................................................................................................................................................................................................................................................................................................11168
4 Lower suspension links, swivel joint............................................................................................................................................................................................................................................................................................................................................................................................................................11170
4.1 Exploded view - lower suspension links, swivel joint......................................................................................................................................................................................................................................................................................................................................................................................................11170
4.2 Removing and installing track control link................................................................................................................................................................................................................................................................................................................................................................................................................11172
4.3 Removing and installing guide link........................................................................................................................................................................................................................................................................................................................................................................................................................11175
4.4 Renewing bush for track control link......................................................................................................................................................................................................................................................................................................................................................................................................................11177
4.5 Removing and installing swivel joint......................................................................................................................................................................................................................................................................................................................................................................................................................11182
4.6 Removing and installing bonded rubber bush for guide link.................................................................................................................................................................................................................................................................................................................................................................................................11183
4.6.1 Removing and installing bonded rubber bush for guide link (conventional bonded rubber bush, 65 mm ∅)................................................................................................................................................................................................................................................................................................................................................11183
4.6.2 Removing and installing bonded rubber bush for guide link (hydraulic bonded rubber bush, 75 mm ∅)...................................................................................................................................................................................................................................................................................................................................................11186
5 Wheel bearing...................................................................................................................................................................................................................................................................................................................................................................................................................................................11190
5.1 Exploded view - wheel bearing.............................................................................................................................................................................................................................................................................................................................................................................................................................11190
5.2 Removing and installing wheel bearing housing.............................................................................................................................................................................................................................................................................................................................................................................................................11193
5.3 Removing and installing wheel bearing unit................................................................................................................................................................................................................................................................................................................................................................................................................11196
5.4 Servicing wheel bearing unit..............................................................................................................................................................................................................................................................................................................................................................................................................................11198
6 Drive shaft.....................................................................................................................................................................................................................................................................................................................................................................................................................................................11203
6.1 Exploded view - drive shaft...............................................................................................................................................................................................................................................................................................................................................................................................................................11203
6.2 Removing and installing drive shaft.......................................................................................................................................................................................................................................................................................................................................................................................................................11205
6.3 Loosening and tightening bolt securing drive shaft........................................................................................................................................................................................................................................................................................................................................................................................................11207
6.4 Dismantling and assembling drive shaft....................................................................................................................................................................................................................................................................................................................................................................................................................11208
6.5 Servicing constant velocity joint.........................................................................................................................................................................................................................................................................................................................................................................................................................11214
6.6 Checking outer constant velocity joint....................................................................................................................................................................................................................................................................................................................................................................................................................11216
6.7 Tightening hose clip on triple roller joint and outer joint...............................................................................................................................................................................................................................................................................................................................................................................................11217
42 – Rear suspension..................................................................................................................................................................................................................................................................................................................................................................................................................................................11219
1 Rear axle.......................................................................................................................................................................................................................................................................................................................................................................................................................................................11219
1.1 Overview - rear axle......................................................................................................................................................................................................................................................................................................................................................................................................................................11219
1.2 Removing and installing rear axle.........................................................................................................................................................................................................................................................................................................................................................................................................................11220
1.2.1 Removing and installing rear axle - front-wheel drive vehicles......................................................................................................................................................................................................................................................................................................................................................................................11220
1.2.2 Removing and installing rear axle - four-wheel drive vehicles.......................................................................................................................................................................................................................................................................................................................................................................................11224
2 Subframe........................................................................................................................................................................................................................................................................................................................................................................................................................................................11231
2.1 Exploded view - subframe..................................................................................................................................................................................................................................................................................................................................................................................................................................11231
2.1.1 Exploded view - subframe, A4 with front-wheel drive.................................................................................................................................................................................................................................................................................................................................................................................................11231
2.1.2 Exploded view - subframe, A5 with front-wheel drive.................................................................................................................................................................................................................................................................................................................................................................................................11235
2.1.3 Exploded view - subframe, A4 with four-wheel drive..................................................................................................................................................................................................................................................................................................................................................................................................11238
2.1.4 Exploded view - subframe, A5 with four-wheel drive..................................................................................................................................................................................................................................................................................................................................................................................................11241
2.2 Servicing subframe........................................................................................................................................................................................................................................................................................................................................................................................................................................11244
2.2.1 Servicing subframe - front-wheel drive vehicles.....................................................................................................................................................................................................................................................................................................................................................................................................11244
2.2.2 Servicing subframe, conventional/hydraulic bonded rubber bushes for subframe - four-wheel drive vehicles............................................................................................................................................................................................................................................................................................................................................11254
2.2.3 Servicing subframe, bonded rubber bush (front) for rear final drive - four-wheel drive vehicles.....................................................................................................................................................................................................................................................................................................................................................11265
2.2.4 Servicing subframe, bonded rubber bush (rear) for rear final drive - four-wheel drive vehicles......................................................................................................................................................................................................................................................................................................................................................11272
2.3 Removing and installing diagonal strut....................................................................................................................................................................................................................................................................................................................................................................................................................11275
2.3.1 Removing and installing diagonal strut - A5 Cabriolet with front-wheel drive........................................................................................................................................................................................................................................................................................................................................................................11275
2.3.2 Removing and installing diagonal strut - A5 Cabriolet with four-wheel drive.........................................................................................................................................................................................................................................................................................................................................................................11276
2.3.3 Removing and installing diagonal strut - A5 Sportback with front-wheel drive........................................................................................................................................................................................................................................................................................................................................................................11277
2.3.4 Removing and installing diagonal strut - A5 Sportback with four-wheel drive.........................................................................................................................................................................................................................................................................................................................................................................11278
3 Anti-roll bar...................................................................................................................................................................................................................................................................................................................................................................................................................................................11280
3.1 Removing and installing anti-roll bar.....................................................................................................................................................................................................................................................................................................................................................................................................................11280
3.1.1 Removing and installing anti-roll bar, front-wheel drive vehicles...................................................................................................................................................................................................................................................................................................................................................................................11280
3.1.2 Removing and installing anti-roll bar, four-wheel drive vehicles....................................................................................................................................................................................................................................................................................................................................................................................11281
4 Suspension links, track rod.....................................................................................................................................................................................................................................................................................................................................................................................................................................11284
4.1 Exploded view - transverse links..........................................................................................................................................................................................................................................................................................................................................................................................................................11284
4.2 Removing and installing upper transverse link.............................................................................................................................................................................................................................................................................................................................................................................................................11286
4.3 Removing and installing lower transverse link.............................................................................................................................................................................................................................................................................................................................................................................................................11288
4.4 Removing and installing track rod.........................................................................................................................................................................................................................................................................................................................................................................................................................11291
5 Suspension strut/shock absorber, spring.........................................................................................................................................................................................................................................................................................................................................................................................................................11294
5.1 Removing and installing shock absorber....................................................................................................................................................................................................................................................................................................................................................................................................................11294
5.1.1 Removing and installing shock absorber - front-wheel drive vehicles.................................................................................................................................................................................................................................................................................................................................................................................11294
5.1.2 Removing and installing shock absorber - four-wheel drive vehicles..................................................................................................................................................................................................................................................................................................................................................................................11296
5.2 Servicing shock absorber..................................................................................................................................................................................................................................................................................................................................................................................................................................11299
5.2.1 Servicing shock absorber - front-wheel drive vehicles...............................................................................................................................................................................................................................................................................................................................................................................................11299
5.2.2 Servicing shock absorber - four-wheel drive vehicles................................................................................................................................................................................................................................................................................................................................................................................................11302
5.3 Removing and installing spring............................................................................................................................................................................................................................................................................................................................................................................................................................11304
5.4 Modifying spring compressing system -VAS 6274-............................................................................................................................................................................................................................................................................................................................................................................................................11313
6 Wheel bearing, trailing arm.....................................................................................................................................................................................................................................................................................................................................................................................................................................11317
6.1 Exploded view - wheel bearing.............................................................................................................................................................................................................................................................................................................................................................................................................................11317
6.1.1 Exploded view - wheel bearing, front-wheel drive vehicles...........................................................................................................................................................................................................................................................................................................................................................................................11317
6.1.2 Exploded view - wheel bearing, four-wheel drive vehicles............................................................................................................................................................................................................................................................................................................................................................................................11321
6.2 Removing and installing wheel bearing housing.............................................................................................................................................................................................................................................................................................................................................................................................................11324
6.2.1 Removing and installing wheel bearing housing, front-wheel drive vehicles...........................................................................................................................................................................................................................................................................................................................................................................11324
6.2.2 Removing and installing wheel bearing housing, four-wheel drive vehicles............................................................................................................................................................................................................................................................................................................................................................................11330
6.3 Removing and installing wheel bearing unit................................................................................................................................................................................................................................................................................................................................................................................................................11335
6.3.1 Removing and installing wheel bearing unit, front-wheel drive vehicles..............................................................................................................................................................................................................................................................................................................................................................................11335
6.3.2 Removing and installing wheel bearing unit, four-wheel drive vehicles...............................................................................................................................................................................................................................................................................................................................................................................11338
6.4 Servicing wheel bearing unit..............................................................................................................................................................................................................................................................................................................................................................................................................................11339
6.5 Renewing bonded rubber bush for wheel bearing housing.....................................................................................................................................................................................................................................................................................................................................................................................................11343
6.5.1 Renewing bonded rubber bush for wheel bearing housing - front-wheel drive vehicles..................................................................................................................................................................................................................................................................................................................................................................11343
6.5.2 Renewing bonded rubber bush for wheel bearing housing - four-wheel drive vehicles...................................................................................................................................................................................................................................................................................................................................................................11347
7 Drive shaft.....................................................................................................................................................................................................................................................................................................................................................................................................................................................11352
7.1 Exploded view - drive shaft...............................................................................................................................................................................................................................................................................................................................................................................................................................11352
7.1.1 Exploded view - drive shaft with 88 mm dia. outer constant velocity joint and 100 mm dia. inner sliding constant velocity joint.....................................................................................................................................................................................................................................................................................................................11352
7.1.2 Exploded view - drive shaft with 100 mm dia. outer constant velocity joint and 108 mm dia. inner sliding constant veloci y joint....................................................................................................................................................................................................................................................................................................................11355
7.1.3 Exploded view - drive shaft with 88/98 mm dia. outer sliding constant velocity joint and 100/108 mm dia. inner sliding constant velocity joint (with cap)...........................................................................................................................................................................................................................................................................................11357
7.2 Removing and installing drive shaft.......................................................................................................................................................................................................................................................................................................................................................................................................................11359
7.3 Dismantling and assembling drive shaft....................................................................................................................................................................................................................................................................................................................................................................................................................11360
7.3.1 Dismantling and assembling drive shaft with 88 mm or 100 mm dia. outer constant velocity joint......................................................................................................................................................................................................................................................................................................................................................11360
7.3.2 Dismantling and assembling drive shaft with 100 mm or 108 mm dia. inner sliding constant velocity joint.............................................................................................................................................................................................................................................................................................................................................11363
7.3.3 Dismantling and assembling drive shaft with 88 mm or 98 mm dia. outer sliding constant velocity joint...............................................................................................................................................................................................................................................................................................................................................11368
7.3.4 Dismantling and assembling drive shaft with 100 mm or 108 mm dia. inner sliding constant velocity joint (with cap)..................................................................................................................................................................................................................................................................................................................................11371
7.4 Loosening and tightening bolt securing drive shaft........................................................................................................................................................................................................................................................................................................................................................................................................11377
7.5 Checking outer constant velocity joint....................................................................................................................................................................................................................................................................................................................................................................................................................11378
7.6 Checking inner constant velocity joint....................................................................................................................................................................................................................................................................................................................................................................................................................11379
43 – Self-levelling suspension........................................................................................................................................................................................................................................................................................................................................................................................................................................11381
1 Electronic damping control......................................................................................................................................................................................................................................................................................................................................................................................................................................11381
1.1 Overview of fitting locations - electronic damping control................................................................................................................................................................................................................................................................................................................................................................................................11381
1.2 Removing and installing electronically controlled damping control unit -J250-.............................................................................................................................................................................................................................................................................................................................................................................11383
1.3 Re-adapting reference position (default position).........................................................................................................................................................................................................................................................................................................................................................................................................11383
1.4 Removing and installing front body acceleration senders -G341-/-G342-.....................................................................................................................................................................................................................................................................................................................................................................................11384
1.5 Removing and installing rear body acceleration sender -G343-..............................................................................................................................................................................................................................................................................................................................................................................................11385
2 Vehicle level senders...........................................................................................................................................................................................................................................................................................................................................................................................................................................11386
2.1 Removing and installing front vehicle level senders -G78-/-G289-..........................................................................................................................................................................................................................................................................................................................................................................................11386
2.2 Removing and installing rear vehicle level senders -G76-/-G77-............................................................................................................................................................................................................................................................................................................................................................................................11388
3 Dynamic Ride Control (DRC)......................................................................................................................................................................................................................................................................................................................................................................................................................................11391
3.1 System description - DRC..................................................................................................................................................................................................................................................................................................................................................................................................................................11391
3.2 Overview of fitting locations - DRC.......................................................................................................................................................................................................................................................................................................................................................................................................................11392
3.3 Exploded view - central valve.............................................................................................................................................................................................................................................................................................................................................................................................................................11394
3.4 Removing and installing central valve.....................................................................................................................................................................................................................................................................................................................................................................................................................11396
3.5 Removing and installing electronically controlled damping control unit -J250-.............................................................................................................................................................................................................................................................................................................................................................................11398
3.6 Checking DRC..............................................................................................................................................................................................................................................................................................................................................................................................................................................11399
3.7 Checking DRC system pressure..............................................................................................................................................................................................................................................................................................................................................................................................................................11400
3.8 Discharging and charging DRC system.......................................................................................................................................................................................................................................................................................................................................................................................................................11401
44 – Wheels, tyres, vehicle geometry..................................................................................................................................................................................................................................................................................................................................................................................................................................11412
1 Wheels, tyres...................................................................................................................................................................................................................................................................................................................................................................................................................................................11412
1.1 Tightening torque for wheel bolts.........................................................................................................................................................................................................................................................................................................................................................................................................................11412
2 Tyre Pressure Monitoring System.................................................................................................................................................................................................................................................................................................................................................................................................................................11413
2.1 System description - Tyre Pressure Monitoring System......................................................................................................................................................................................................................................................................................................................................................................................................11413
2.2 Overview of fitting locations - Tyre Pressure Monitoring System...........................................................................................................................................................................................................................................................................................................................................................................................11414
2.3 Exploded view - tyre pressure sensor......................................................................................................................................................................................................................................................................................................................................................................................................................11416
2.4 Removing and installing Tyre Pressure Monitoring System control unit -J502-...............................................................................................................................................................................................................................................................................................................................................................................11416
2.5 Removing and installing tyre pressure sensor -G222-/-G223-/-G224-/-G225-..................................................................................................................................................................................................................................................................................................................................................................................11419
2.6 Changing tyres on vehicles with Tyre Pressure Monitoring System...........................................................................................................................................................................................................................................................................................................................................................................................11420
3 Wheel alignment.................................................................................................................................................................................................................................................................................................................................................................................................................................................11422
3.1 Notes on wheel alignment..................................................................................................................................................................................................................................................................................................................................................................................................................................11422
3.2 Test requirements.........................................................................................................................................................................................................................................................................................................................................................................................................................................11423
3.3 Preparations for measurement..............................................................................................................................................................................................................................................................................................................................................................................................................................11424
3.4 Wheel alignment specifications............................................................................................................................................................................................................................................................................................................................................................................................................................11425
3.4.1 Wheel alignment specifications - Audi A4............................................................................................................................................................................................................................................................................................................................................................................................................11425
3.4.2 Wheel alignment specifications - Audi A5............................................................................................................................................................................................................................................................................................................................................................................................................11428
3.5 Wheel alignment procedure.................................................................................................................................................................................................................................................................................................................................................................................................................................11434
3.6 When does wheel alignment have to be checked?.............................................................................................................................................................................................................................................................................................................................................................................................................11435
3.7 Explanatory notes on production control numbers (PR Nos.).................................................................................................................................................................................................................................................................................................................................................................................................11436
3.7.1 Explanatory notes on production control numbers (PR Nos.) - Audi A4.................................................................................................................................................................................................................................................................................................................................................................................11436
3.7.2 Explanatory notes on production control numbers (PR Nos.) - Audi A5.................................................................................................................................................................................................................................................................................................................................................................................11437
3.8 Adjusting camber at front wheels..........................................................................................................................................................................................................................................................................................................................................................................................................................11438
3.9 Adjusting camber at rear wheels...........................................................................................................................................................................................................................................................................................................................................................................................................................11443
3.10 Adjusting toe setting at rear wheels.....................................................................................................................................................................................................................................................................................................................................................................................................................11443
3.11 Adjusting toe setting at front wheels....................................................................................................................................................................................................................................................................................................................................................................................................................11444
3.12 Wheel runout compensation................................................................................................................................................................................................................................................................................................................................................................................................................................11445
3.13 Setting vehicle to initial position for wheel alignment..................................................................................................................................................................................................................................................................................................................................................................................................11445
3.14 Checking centre position of rack (mechanical method).....................................................................................................................................................................................................................................................................................................................................................................................................11446
3.15 Checking full steering lock..............................................................................................................................................................................................................................................................................................................................................................................................................................11446
4 Dynamic steering................................................................................................................................................................................................................................................................................................................................................................................................................................................11447
4.1 Exploded view - dynamic steering..........................................................................................................................................................................................................................................................................................................................................................................................................................11447
4.2 Removing and installing active steering control unit -J792-...............................................................................................................................................................................................................................................................................................................................................................................................11448
4.3 Basic setting for dynamic steering........................................................................................................................................................................................................................................................................................................................................................................................................................11449
4.4 Removing and installing active steering safety lock actuator -F437-.......................................................................................................................................................................................................................................................................................................................................................................................11452
5 Adaptive cruise control.........................................................................................................................................................................................................................................................................................................................................................................................................................................11455
5.1 Exploded view of sensor for adaptive cruise control -G550-................................................................................................................................................................................................................................................................................................................................................................................................11455
5.2 Removing and installing sensor for adaptive cruise control -G550-.........................................................................................................................................................................................................................................................................................................................................................................................11456
5.3 Renewing clip on adaptive cruise control unit (from Model Year 2012 onwards)..............................................................................................................................................................................................................................................................................................................................................................................11458
5.4 Preparing ACC setting device -VAS 6190- for adjustment procedure..........................................................................................................................................................................................................................................................................................................................................................................................11459
5.5 Calibrating adaptive cruise control.......................................................................................................................................................................................................................................................................................................................................................................................................................11461
5.5.1 Calibrating adaptive cruise control - adjustment procedure using ACC setting device -VAS 6190-......................................................................................................................................................................................................................................................................................................................................................11461
5.5.2 Calibrating adaptive cruise control - adjustment procedure using ACC setting device -VAS 6430-......................................................................................................................................................................................................................................................................................................................................................11466
6 Lane departure warning (Audi lane assist).......................................................................................................................................................................................................................................................................................................................................................................................................................11472
6.1 Removing and installing lane departure warning control unit -J759- and backlight masking screen...........................................................................................................................................................................................................................................................................................................................................................11472
6.2 Calibrating lane departure warning system.................................................................................................................................................................................................................................................................................................................................................................................................................11472
48 – Steering.........................................................................................................................................................................................................................................................................................................................................................................................................................................................11479
1 Steering wheel..................................................................................................................................................................................................................................................................................................................................................................................................................................................11479
1.1 Exploded view - steering wheel............................................................................................................................................................................................................................................................................................................................................................................................................................11479
1.2 Removing and installing steering wheel....................................................................................................................................................................................................................................................................................................................................................................................................................11479
2 Steering column.................................................................................................................................................................................................................................................................................................................................................................................................................................................11482
2.1 Exploded view - steering column...........................................................................................................................................................................................................................................................................................................................................................................................................................11482
2.2 Removing and installing steering column...................................................................................................................................................................................................................................................................................................................................................................................................................11483
2.3 Handling and transporting steering column.................................................................................................................................................................................................................................................................................................................................................................................................................11488
2.4 Checking steering column for damage.......................................................................................................................................................................................................................................................................................................................................................................................................................11490
2.5 Removing and installing intermediate steering shaft.......................................................................................................................................................................................................................................................................................................................................................................................................11490
2.6 Removing and installing control unit for electronic steering column lock -J764-...........................................................................................................................................................................................................................................................................................................................................................................11493
3 Steering rack...................................................................................................................................................................................................................................................................................................................................................................................................................................................11496
3.1 Exploded view - steering rack.............................................................................................................................................................................................................................................................................................................................................................................................................................11496
3.1.1 Exploded view - steering rack, electromechanical steering rack......................................................................................................................................................................................................................................................................................................................................................................................11496
3.1.2 Exploded view - steering rack, hydraulic power steering rack........................................................................................................................................................................................................................................................................................................................................................................................11498
3.2 Removing and installing steering rack.....................................................................................................................................................................................................................................................................................................................................................................................................................11500
3.2.1 Removing and installing steering rack - electromechanical steering rack.............................................................................................................................................................................................................................................................................................................................................................................11500
3.2.2 Removing and installing steering rack - hydraulic power steering rack...............................................................................................................................................................................................................................................................................................................................................................................11503
3.3 Centralising steering.....................................................................................................................................................................................................................................................................................................................................................................................................................................11509
3.3.1 Centralising steering - electromechanical steering rack.............................................................................................................................................................................................................................................................................................................................................................................................11509
3.3.2 Centralising steering - hydraulic power steering rack...............................................................................................................................................................................................................................................................................................................................................................................................11509
3.4 Servicing steering rack...................................................................................................................................................................................................................................................................................................................................................................................................................................11510
3.4.1 Servicing steering rack - electromechanical steering rack...........................................................................................................................................................................................................................................................................................................................................................................................11510
3.4.2 Servicing steering rack - hydraulic power steering rack.............................................................................................................................................................................................................................................................................................................................................................................................11513
3.5 Removing and installing boot..............................................................................................................................................................................................................................................................................................................................................................................................................................11516
3.5.1 Removing and installing boot - electromechanical steering rack......................................................................................................................................................................................................................................................................................................................................................................................11516
3.5.2 Removing and installing boot - hydraulic power steering rack........................................................................................................................................................................................................................................................................................................................................................................................11521
3.6 Removing and installing track rod.........................................................................................................................................................................................................................................................................................................................................................................................................................11526
3.6.1 Removing and installing track rod - electromechanical steering rack.................................................................................................................................................................................................................................................................................................................................................................................11526
3.6.2 Removing and installing track rod - hydraulic power steering rack...................................................................................................................................................................................................................................................................................................................................................................................11530
3.7 Removing and installing track rod ball joint..............................................................................................................................................................................................................................................................................................................................................................................................................11534
3.7.1 Removing and installing track rod ball joint - electromechanical steering rack......................................................................................................................................................................................................................................................................................................................................................................11534
3.7.2 Removing and installing track rod ball joint - hydraulic power steering rack........................................................................................................................................................................................................................................................................................................................................................................11536
3.8 Adjusting steering rack...................................................................................................................................................................................................................................................................................................................................................................................................................................11539
3.9 Removing and installing servotronic solenoid valve -N119-.................................................................................................................................................................................................................................................................................................................................................................................................11540
4 Sensors.........................................................................................................................................................................................................................................................................................................................................................................................................................................................11542
4.1 Removing and installing steering angle sender -G85-.......................................................................................................................................................................................................................................................................................................................................................................................................11542
5 Hydraulic power steering........................................................................................................................................................................................................................................................................................................................................................................................................................................11544
5.1 Overview of fitting locations - hydraulic power steering..................................................................................................................................................................................................................................................................................................................................................................................................11544
5.2 Exploded view - hydraulic lines, reservoir................................................................................................................................................................................................................................................................................................................................................................................................................11563
5.2.1 Exploded view - hydraulic lines, reservoir (vehicles with 4-cylinder diesel engine, vehicles with dynamic steering).................................................................................................................................................................................................................................................................................................................................11563
5.2.2 Exploded view - hydraulic lines, reservoir (vehicles with 4-cylinder diesel engine, vehicles without dynamic steering)..............................................................................................................................................................................................................................................................................................................................11566
5.2.3 Exploded view - hydraulic lines, reservoir (vehicles with 4-cylinder TFSI engine, vehicles with dynamic steering)...................................................................................................................................................................................................................................................................................................................................11568
5.2.4 Exploded view - hydraulic lines, reservoir (vehicles with 4-cylinder TFSI engine, vehicles without dynamic steering)................................................................................................................................................................................................................................................................................................................................11571
5.2.5 Exploded view - hydraulic lines, reservoir (vehicles with 6-cylinder diesel engine, vehicles with dynamic steering).................................................................................................................................................................................................................................................................................................................................11574
5.2.6 Exploded view - hydraulic lines, reservoir (vehicles with 6-cylinder diesel engine, vehicles without dynamic steering)..............................................................................................................................................................................................................................................................................................................................11576
5.2.7 Exploded view - hydraulic lines, reservoir (vehicles with 6-cylinder FSI engine, vehicles with dynamic steering)....................................................................................................................................................................................................................................................................................................................................11579
5.2.8 Exploded view - hydraulic lines, reservoir (vehicles with 6-cylinder FSI engine, vehicles without dynamic steering).................................................................................................................................................................................................................................................................................................................................11582
5.2.9 Exploded view - hydraulic lines, reservoir (vehicles with 6-cylinder TFSI engine, vehicles with dynamic steering)...................................................................................................................................................................................................................................................................................................................................11585
5.2.10 Exploded view - hydraulic lines, reservoir (vehicles with 6-cylinder TFSI engine, vehicles without dynamic steering)...............................................................................................................................................................................................................................................................................................................................11588
5.2.11 Exploded view - hydraulic lines, reservoir (vehicles with 8-cylinder FSI engine, vehicles with dynamic steering)...................................................................................................................................................................................................................................................................................................................................11590
5.2.12 Exploded view - hydraulic lines, reservoir (vehicles with 8-cylinder FSI engine, vehicles without dynamic steering)................................................................................................................................................................................................................................................................................................................................11593
5.3 Exploded view - power steering pump.......................................................................................................................................................................................................................................................................................................................................................................................................................11597
5.3.1 Exploded view - power steering pump (vehicles with 4-cylinder diesel engine, vehicles with dynamic steering)........................................................................................................................................................................................................................................................................................................................................11597
5.3.2 Exploded view - power steering pump (vehicles with 4-cylinder diesel engine, vehicles without dynamic steering).....................................................................................................................................................................................................................................................................................................................................11599
5.3.3 Exploded view - power steering pump (vehicles with 4-cylinder TFSI engine, vehicles with dynamic steering)..........................................................................................................................................................................................................................................................................................................................................11600
5.3.4 Exploded view - power steering pump (vehicles with 4-cylinder TFSI engine, vehicles without dynamic steering).......................................................................................................................................................................................................................................................................................................................................11602
5.3.5 Exploded view - power steering pump (vehicles with 6-cylinder diesel engine, vehicles with dynamic steering)........................................................................................................................................................................................................................................................................................................................................11603
5.3.6 Exploded view - power steering pump (vehicles with 6-cylinder diesel engine, vehicles without dynamic steering).....................................................................................................................................................................................................................................................................................................................................11605
5.3.7 Exploded view - power steering pump (vehicles with 6-cylinder FSI engine, vehicles with dynamic steering)...........................................................................................................................................................................................................................................................................................................................................11606
5.3.8 Exploded view - power steering pump (vehicles with 6-cylinder FSI engine, vehicles without dynamic steering)........................................................................................................................................................................................................................................................................................................................................11608
5.3.9 Exploded view - power steering pump (vehicles with 6-cylinder TFSI engine, vehicles with dynamic steering)..........................................................................................................................................................................................................................................................................................................................................11610
5.3.10 Exploded view - power steering pump (vehicles with 6-cylinder TFSI engine, vehicles without dynamic steering)......................................................................................................................................................................................................................................................................................................................................11612
5.3.11 Exploded view - power steering pump (vehicles with 8-cylinder FSI engine, vehicles with dynamic steering)..........................................................................................................................................................................................................................................................................................................................................11614
5.3.12 Exploded view - power steering pump (vehicles with 8-cylinder FSI engine, vehicles without dynamic steering).......................................................................................................................................................................................................................................................................................................................................11616
5.4 Checking fluid level in power steering system.............................................................................................................................................................................................................................................................................................................................................................................................................11618
5.5 Bleeding steering system after repairs....................................................................................................................................................................................................................................................................................................................................................................................................................11619
5.6 Checking steering system for leaks........................................................................................................................................................................................................................................................................................................................................................................................................................11620
5.7 Checking delivery pressure of power steering pump.........................................................................................................................................................................................................................................................................................................................................................................................................11621
5.7.1 Checking delivery pressure of power steering pump (vehicles with 4-cylinder diesel engine, vehicles with and without dynamic steering)..............................................................................................................................................................................................................................................................................................................11621
5.7.2 Checking delivery pressure of power steering pump (vehicles with 4-cylinder TFSI engine, vehicles with and without dynamic steering)................................................................................................................................................................................................................................................................................................................11627
5.7.3 Checking delivery pressure of power steering pump (vehicles with 6-cylinder diesel engine, vehicles with and without dynamic steering)..............................................................................................................................................................................................................................................................................................................11632
5.7.4 Checking delivery pressure of power steering pump (vehicles with 6-cylinder FSI engine, vehicles with and without dynamic steering).................................................................................................................................................................................................................................................................................................................11638
5.7.5 Checking delivery pressure of power steering pump (vehicles with 6-cylinder TFSI engine, vehicles with and without dynamic steering)................................................................................................................................................................................................................................................................................................................11643
5.7.6 Checking delivery pressure of power steering pump (vehicles with 8-cylinder FSI engine, vehicles with and without dynamic steering).................................................................................................................................................................................................................................................................................................................11648
5.8 Removing and installing power steering pump...............................................................................................................................................................................................................................................................................................................................................................................................................11653
5.8.1 Removing and installing power steering pump (vehicles with 4-cylinder diesel engine, vehicles with dynamic steering)................................................................................................................................................................................................................................................................................................................................11653
5.8.2 Removing and installing power steering pump (vehicles with 4-cylinder diesel engine, vehicles without dynamic steering).............................................................................................................................................................................................................................................................................................................................11660
5.8.3 Removing and installing power steering pump (vehicles with 4-cylinder TFSI engine, vehicles with dynamic steering)..................................................................................................................................................................................................................................................................................................................................11666
5.8.4 Removing and installing power steering pump (vehicles with 4-cylinder TFSI engine, vehicles without dynamic steering)...............................................................................................................................................................................................................................................................................................................................11672
5.8.5 Removing and installing power steering pump (vehicles with 6-cylinder diesel engine, vehicles with dynamic steering)................................................................................................................................................................................................................................................................................................................................11677
5.8.6 Removing and installing power steering pump (vehicles with 6-cylinder diesel engine, vehicles without dynamic steering).............................................................................................................................................................................................................................................................................................................................11687
5.8.7 Removing and installing power steering pump (vehicles with 6-cylinder FSI engine, vehicles with dynamic steering)...................................................................................................................................................................................................................................................................................................................................11696
5.8.8 Removing and installing power steering pump (vehicles with 6-cylinder FSI engine, vehicles without dynamic steering)................................................................................................................................................................................................................................................................................................................................11705
5.8.9 Removing and installing power steering pump (vehicles with 6-cylinder TFSI engine, vehicles with dynamic steering)..................................................................................................................................................................................................................................................................................................................................11714
5.8.10 Removing and installing power steering pump (vehicles with 6-cylinder TFSI engine, vehicles without dynamic steering)..............................................................................................................................................................................................................................................................................................................................11723
5.8.11 Removing and installing power steering pump (vehicles with 8-cylinder FSI engine, vehicles with dynamic steering)..................................................................................................................................................................................................................................................................................................................................11732
5.8.12 Removing and installing power steering pump (vehicles with 8-cylinder FSI engine, vehicles without dynamic steering)...............................................................................................................................................................................................................................................................................................................................11737
5.9 Removing and installing hydraulic fluid cooler............................................................................................................................................................................................................................................................................................................................................................................................................11742
5.9.1 Removing and installing hydraulic fluid cooler (vehicles with dynamic steering and vehicles with 8-cylinder FSI engine).............................................................................................................................................................................................................................................................................................................................11742
5.9.2 Removing and installing hydraulic fluid cooler (RS models)..........................................................................................................................................................................................................................................................................................................................................................................................11745
5.10 Installation position of hoses on fluid reservoir, hydraulic fluid cooler and return line................................................................................................................................................................................................................................................................................................................................................................11748
Running_gear__front-wheel_drive_and_four-wheel_drive......................................................................................................................................................................................................................................................................................................................................................................................................................11749
00 – Technical data...................................................................................................................................................................................................................................................................................................................................................................................................................................................11757
1 Technical data..................................................................................................................................................................................................................................................................................................................................................................................................................................................11757
1.1 Running gear..............................................................................................................................................................................................................................................................................................................................................................................................................................................11757
1.2 Steering..................................................................................................................................................................................................................................................................................................................................................................................................................................................11759
2 Proper disposal procedures for oil-filled and gas-filled components.............................................................................................................................................................................................................................................................................................................................................................................................11760
2.1 Releasing gas and draining gas-filled shock absorbers (front).............................................................................................................................................................................................................................................................................................................................................................................................11760
2.2 Releasing gas in gas-filled shock absorbers (rear)........................................................................................................................................................................................................................................................................................................................................................................................................11761
2.3 Draining power steering box...............................................................................................................................................................................................................................................................................................................................................................................................................................11762
3 Checking shock absorbers........................................................................................................................................................................................................................................................................................................................................................................................................................................11763
3.1 Leaks at shock absorbers..................................................................................................................................................................................................................................................................................................................................................................................................................................11763
3.2 Noises from shock absorbers...............................................................................................................................................................................................................................................................................................................................................................................................................................11763
3.3 Checking shock absorbers when removed.....................................................................................................................................................................................................................................................................................................................................................................................................................11763
3.4 Checking shock absorbers on shock tester..................................................................................................................................................................................................................................................................................................................................................................................................................11764
40 – Front suspension.................................................................................................................................................................................................................................................................................................................................................................................................................................................11767
1 General notes...................................................................................................................................................................................................................................................................................................................................................................................................................................................11767
1.1 General information.......................................................................................................................................................................................................................................................................................................................................................................................................................................11767
1.2 Contact corrosion.........................................................................................................................................................................................................................................................................................................................................................................................................................................11768
1.3 Repairing damaged threads in longitudinal member (subframe to body).......................................................................................................................................................................................................................................................................................................................................................................................11768
1.4 Lifting suspension to unladen position (vehicles with coil springs).......................................................................................................................................................................................................................................................................................................................................................................................11769
1.5 Exploded views of front axle..............................................................................................................................................................................................................................................................................................................................................................................................................................11771
2 Subframe, cross brace, diagonal strut, anti-roll bar, coupling rod, subframe shield.............................................................................................................................................................................................................................................................................................................................................................................11772
2.1 Exploded view of subframe, cross brace, anti-roll bar, coupling rod (vehicles up to August 2007)..........................................................................................................................................................................................................................................................................................................................................................11773
2.2 Exploded view of subframe, cross brace, diagonal strut, anti-roll bar, coupling rod, subframe shield (vehicles from September 2007 onwards)...............................................................................................................................................................................................................................................................................................................11775
2.3 Removing and installing subframe..........................................................................................................................................................................................................................................................................................................................................................................................................................11778
2.4 Removing and installing subframe cross brace (Coupé/Sportback)............................................................................................................................................................................................................................................................................................................................................................................................11783
2.5 Removing and installing subframe cross brace (Cabriolet)..................................................................................................................................................................................................................................................................................................................................................................................................11784
2.6 Removing and installing diagonal strut (Cabriolet)........................................................................................................................................................................................................................................................................................................................................................................................................11786
2.7 Removing and installing anti-roll bar.....................................................................................................................................................................................................................................................................................................................................................................................................................11787
2.8 Removing and installing coupling rod......................................................................................................................................................................................................................................................................................................................................................................................................................11789
2.9 Removing and installing subframe shield...................................................................................................................................................................................................................................................................................................................................................................................................................11791
3 Suspension strut with mounting bracket, shock absorber fork, upper links, body brace............................................................................................................................................................................................................................................................................................................................................................................11792
3.1 Exploded view of suspension strut with mounting bracket, shock absorber fork, upper links, body brace.....................................................................................................................................................................................................................................................................................................................................................11792
3.2 Removing and installing suspension strut with mounting bracket............................................................................................................................................................................................................................................................................................................................................................................................11793
3.3 Servicing suspension strut and mounting bracket...........................................................................................................................................................................................................................................................................................................................................................................................................11799
3.4 Removing and installing shock absorber fork...............................................................................................................................................................................................................................................................................................................................................................................................................11805
3.5 Removing and installing upper links.......................................................................................................................................................................................................................................................................................................................................................................................................................11809
3.6 Renewing bushes for front and rear upper links............................................................................................................................................................................................................................................................................................................................................................................................................11810
3.7 Removing and installing body brace........................................................................................................................................................................................................................................................................................................................................................................................................................11811
4 Track control link, swivel joint, guide link, vehicle level sender..............................................................................................................................................................................................................................................................................................................................................................................................11813
4.1 Exploded view of track control link, swivel joint, guide link, vehicle level sender.......................................................................................................................................................................................................................................................................................................................................................................11813
4.2 Removing and installing track control link................................................................................................................................................................................................................................................................................................................................................................................................................11815
4.3 Renewing bush for track control link......................................................................................................................................................................................................................................................................................................................................................................................................................11818
4.4 Removing and installing swivel joint......................................................................................................................................................................................................................................................................................................................................................................................................................11823
4.5 Removing and installing guide link........................................................................................................................................................................................................................................................................................................................................................................................................................11824
4.6 Renewing conventional bonded rubber bush (65 mm ∅) for guide link.........................................................................................................................................................................................................................................................................................................................................................................................11827
4.7 Renewing hydraulic bonded rubber bush (75 mm ∅) for guide link............................................................................................................................................................................................................................................................................................................................................................................................11829
4.8 Removing and installing vehicle level sender..............................................................................................................................................................................................................................................................................................................................................................................................................11832
5 Wheel bearing housing, wheel bearing unit.......................................................................................................................................................................................................................................................................................................................................................................................................................11835
5.1 Exploded view of wheel bearing housing, wheel bearing unit................................................................................................................................................................................................................................................................................................................................................................................................11835
5.2 Removing and installing wheel bearing housing.............................................................................................................................................................................................................................................................................................................................................................................................................11838
5.3 Removing and installing wheel bearing unit................................................................................................................................................................................................................................................................................................................................................................................................................11841
5.4 Servicing wheel bearing unit..............................................................................................................................................................................................................................................................................................................................................................................................................................11844
6 Drive shaft.....................................................................................................................................................................................................................................................................................................................................................................................................................................................11848
6.1 General notes:............................................................................................................................................................................................................................................................................................................................................................................................................................................11848
6.2 Loosening and tightening bolt securing drive shaft to wheel hub...........................................................................................................................................................................................................................................................................................................................................................................................11848
6.3 Removing and installing drive shaft.......................................................................................................................................................................................................................................................................................................................................................................................................................11849
6.4 Exploded view of drive shaft..............................................................................................................................................................................................................................................................................................................................................................................................................................11852
6.5 Dismantling and assembling peened triple roller joint AAR 2600 i or 3300 i................................................................................................................................................................................................................................................................................................................................................................................11855
6.6 Servicing outer constant velocity joint...................................................................................................................................................................................................................................................................................................................................................................................................................11861
6.7 Checking outer constant velocity joint....................................................................................................................................................................................................................................................................................................................................................................................................................11863
6.8 Tightening large and small clips on triple roller joint and outer joint...................................................................................................................................................................................................................................................................................................................................................................................11864
42 – Rear suspension..................................................................................................................................................................................................................................................................................................................................................................................................................................................11866
1 General notes...................................................................................................................................................................................................................................................................................................................................................................................................................................................11866
1.1 General information.......................................................................................................................................................................................................................................................................................................................................................................................................................................11866
1.2 Contact corrosion.........................................................................................................................................................................................................................................................................................................................................................................................................................................11867
1.3 Repairing damaged threads in longitudinal member (subframe to body).......................................................................................................................................................................................................................................................................................................................................................................................11867
1.4 Lifting suspension to unladen position (vehicles with coil springs).......................................................................................................................................................................................................................................................................................................................................................................................11868
1.5 Rear axle - overview......................................................................................................................................................................................................................................................................................................................................................................................................................................11870
2 Subframe, anti-roll bar, coupling rod, diagonal strut - front-wheel drive vehicles..............................................................................................................................................................................................................................................................................................................................................................................11871
2.1 Exploded view of subframe, anti-roll bar, coupling rod, diagonal strut - front-wheel drive vehicles.......................................................................................................................................................................................................................................................................................................................................................11871
2.2 Removing and installing subframe with attachments - front-wheel drive vehicles............................................................................................................................................................................................................................................................................................................................................................................11874
2.3 Renewing conventional/hydraulic bonded rubber bushes for subframe - front-wheel drive vehicles............................................................................................................................................................................................................................................................................................................................................................11879
2.4 Removing and installing coupling rod and anti-roll bar - front-wheel drive vehicles.......................................................................................................................................................................................................................................................................................................................................................................11889
2.5 Removing and installing diagonal strut (Cabriolet)........................................................................................................................................................................................................................................................................................................................................................................................................11891
2.6 Removing and installing diagonal strut (Sportback)........................................................................................................................................................................................................................................................................................................................................................................................................11892
3 Subframe, anti-roll bar, coupling rod, diagonal strut - four-wheel drive vehicles...............................................................................................................................................................................................................................................................................................................................................................................11894
3.1 Exploded view of subframe, anti-roll bar, coupling rod, diagonal strut - four-wheel drive vehicles........................................................................................................................................................................................................................................................................................................................................................11895
3.2 Removing and installing subframe with attachments - four-wheel drive vehicles.............................................................................................................................................................................................................................................................................................................................................................................11898
3.3 Renewing conventional/hydraulic bonded rubber bushes for subframe - four-wheel drive vehicles.............................................................................................................................................................................................................................................................................................................................................................11904
3.4 Renewing front bonded rubber bush for rear final drive - four-wheel drive vehicles........................................................................................................................................................................................................................................................................................................................................................................11914
3.5 Renewing rear bonded rubber bushes for rear final drive - four-wheel drive vehicles.......................................................................................................................................................................................................................................................................................................................................................................11921
3.6 Removing and installing coupling rod with anti-roll bar - four-wheel drive vehicles.......................................................................................................................................................................................................................................................................................................................................................................11924
3.7 Removing and installing diagonal strut (Cabriolet)........................................................................................................................................................................................................................................................................................................................................................................................................11926
3.8 Removing and installing diagonal strut (Sportback)........................................................................................................................................................................................................................................................................................................................................................................................................11927
4 Upper transverse link, track rod, coil spring, lower transverse link, vehicle level sender......................................................................................................................................................................................................................................................................................................................................................................11929
4.1 Exploded view of upper transverse link, track rod, coil spring, lower transverse link, vehicle level sender...............................................................................................................................................................................................................................................................................................................................................11929
4.2 Removing and installing lower transverse link.............................................................................................................................................................................................................................................................................................................................................................................................................11931
4.3 Removing and installing upper transverse link.............................................................................................................................................................................................................................................................................................................................................................................................................11934
4.4 Removing and installing track rod.........................................................................................................................................................................................................................................................................................................................................................................................................................11936
4.5 Modifying spring compressing system -VAS 6274-............................................................................................................................................................................................................................................................................................................................................................................................................11937
4.6 Removing and installing coil spring.......................................................................................................................................................................................................................................................................................................................................................................................................................11940
4.7 Removing and installing vehicle level sender..............................................................................................................................................................................................................................................................................................................................................................................................................11950
5 Wheel bearing housing, wheel bearing unit, shock absorber - front-wheel drive vehicles..........................................................................................................................................................................................................................................................................................................................................................................11952
5.1 Exploded view of wheel bearing housing, wheel bearing unit, shock absorber for coil springs - front-wheel drive vehicles..................................................................................................................................................................................................................................................................................................................................11952
5.2 Removing and installing wheel bearing housing - front-wheel drive vehicles................................................................................................................................................................................................................................................................................................................................................................................11955
5.3 Removing and installing wheel bearing unit - front-wheel drive vehicles...................................................................................................................................................................................................................................................................................................................................................................................11961
5.4 Renewing bonded rubber bush for wheel bearing housing - front-wheel drive vehicles........................................................................................................................................................................................................................................................................................................................................................................11965
5.5 Removing and installing shock absorber - front-wheel drive vehicles.......................................................................................................................................................................................................................................................................................................................................................................................11969
5.6 Servicing shock absorber - front-wheel drive vehicles.....................................................................................................................................................................................................................................................................................................................................................................................................11971
6 Wheel bearing housing, wheel bearing unit, shock absorber - four-wheel drive vehicles...........................................................................................................................................................................................................................................................................................................................................................................11974
6.1 Exploded view of wheel bearing housing, wheel bearing unit, shock absorber for coil springs - four-wheel drive vehicles...................................................................................................................................................................................................................................................................................................................................11975
6.2 Removing and installing wheel bearing housing - four-wheel drive vehicles.................................................................................................................................................................................................................................................................................................................................................................................11978
6.3 Removing and installing wheel bearing unit - four-wheel drive vehicles....................................................................................................................................................................................................................................................................................................................................................................................11982
6.4 Servicing wheel bearing unit - four-wheel drive vehicles..................................................................................................................................................................................................................................................................................................................................................................................................11983
6.5 Renewing bonded rubber bush for wheel bearing housing - four-wheel drive vehicles.........................................................................................................................................................................................................................................................................................................................................................................11986
6.6 Removing and installing shock absorber - four-wheel drive vehicles........................................................................................................................................................................................................................................................................................................................................................................................11990
6.7 Servicing shock absorber - four-wheel drive vehicles......................................................................................................................................................................................................................................................................................................................................................................................................11993
7 Drive shaft.....................................................................................................................................................................................................................................................................................................................................................................................................................................................11996
7.1 General notes:............................................................................................................................................................................................................................................................................................................................................................................................................................................11996
7.2 Loosening and tightening bolt securing drive shaft to wheel hub...........................................................................................................................................................................................................................................................................................................................................................................................11996
7.3 Removing and installing drive shaft.......................................................................................................................................................................................................................................................................................................................................................................................................................11997
7.4 Exploded view of drive shaft with 88 mm dia. outer constant velocity joint and 100 mm dia. inner sliding constant velocity joint..........................................................................................................................................................................................................................................................................................................................11999
7.5 Exploded view of drive shaft with 100 mm dia. outer constant velocity joint and 108 mm dia. inner sliding constant velocity joint.........................................................................................................................................................................................................................................................................................................................12001
7.6 Exploded view of drive shaft with 88/98 mm dia. outer sliding constant velocity joint and 100/108 mm dia. inner sliding co
stant velocity joint (with cap)................................................................................................................................................................................................................................................................................................12003
7.7 Servicing outer constant velocity joint (88 mm or 100 mm dia.)............................................................................................................................................................................................................................................................................................................................................................................................12005
7.8 Servicing inner sliding constant velocity joint (100 mm or 108 mm dia.)...................................................................................................................................................................................................................................................................................................................................................................................12007
7.9 Servicing outer sliding constant velocity joint (88 mm or 98 mm dia.).....................................................................................................................................................................................................................................................................................................................................................................................12012
7.10 Servicing inner sliding constant velocity joint with cap (100 mm or 108 mm dia.).........................................................................................................................................................................................................................................................................................................................................................................12015
7.11 Checking outer constant velocity joint...................................................................................................................................................................................................................................................................................................................................................................................................................12021
7.12 Checking inner sliding CV joint..........................................................................................................................................................................................................................................................................................................................................................................................................................12022
43 – Self-levelling suspension........................................................................................................................................................................................................................................................................................................................................................................................................................................12025
1 General notes...................................................................................................................................................................................................................................................................................................................................................................................................................................................12025
1.1 General information.......................................................................................................................................................................................................................................................................................................................................................................................................................................12025
1.2 Gaskets and seals.........................................................................................................................................................................................................................................................................................................................................................................................................................................12025
1.3 Bolts and nuts............................................................................................................................................................................................................................................................................................................................................................................................................................................12026
1.4 Electrical components.....................................................................................................................................................................................................................................................................................................................................................................................................................................12026
2 Electronic damping control......................................................................................................................................................................................................................................................................................................................................................................................................................................12027
2.1 Exploded view of electronic damping control...............................................................................................................................................................................................................................................................................................................................................................................................................12027
2.2 Removing and installing electronically controlled damping control unit -J250-.............................................................................................................................................................................................................................................................................................................................................................................12028
2.3 Re-adapting reference position with vehicle diagnosis, testing and information system -VAS 5051B-.........................................................................................................................................................................................................................................................................................................................................................12029
2.4 Removing and installing front left body acceleration sender -G341- and front right body acceleration sender -G342-........................................................................................................................................................................................................................................................................................................................................12030
2.5 Removing and installing rear body acceleration sender -G343-..............................................................................................................................................................................................................................................................................................................................................................................................12031
3 Dynamic Ride Control (DRC)......................................................................................................................................................................................................................................................................................................................................................................................................................................12032
3.1 General information on DRC................................................................................................................................................................................................................................................................................................................................................................................................................................12032
3.2 Fitting locations.........................................................................................................................................................................................................................................................................................................................................................................................................................................12034
3.3 Removing and installing electronically controlled damping control unit -J250- (DRC).......................................................................................................................................................................................................................................................................................................................................................................12034
3.4 Exploded view of central valves...........................................................................................................................................................................................................................................................................................................................................................................................................................12036
3.5 DRC fault-finding.........................................................................................................................................................................................................................................................................................................................................................................................................................................12037
3.6 DRC system pressure test..................................................................................................................................................................................................................................................................................................................................................................................................................................12038
3.7 Discharging and charging Dynamic Ride Control (DRC).......................................................................................................................................................................................................................................................................................................................................................................................................12040
3.8 Removing and installing central valve.....................................................................................................................................................................................................................................................................................................................................................................................................................12049
44 – Wheels, tyres, vehicle geometry..................................................................................................................................................................................................................................................................................................................................................................................................................................12052
1 Wheels and tyres................................................................................................................................................................................................................................................................................................................................................................................................................................................12052
2 Tyre monitor display (TMD+).....................................................................................................................................................................................................................................................................................................................................................................................................................................12053
2.1 General notes.............................................................................................................................................................................................................................................................................................................................................................................................................................................12053
3 Tyre Pressure Monitoring System (TPMS)..........................................................................................................................................................................................................................................................................................................................................................................................................................12055
3.1 General notes.............................................................................................................................................................................................................................................................................................................................................................................................................................................12055
3.2 Overview of Tyre Pressure Monitoring System...............................................................................................................................................................................................................................................................................................................................................................................................................12056
3.3 Operation of Tyre Pressure Monitoring System..............................................................................................................................................................................................................................................................................................................................................................................................................12056
3.4 Removing and installing tyre pressure monitor control unit -J502-.........................................................................................................................................................................................................................................................................................................................................................................................12058
3.5 Exploded view of tyre pressure sensor.....................................................................................................................................................................................................................................................................................................................................................................................................................12061
3.6 Changing a tyre...........................................................................................................................................................................................................................................................................................................................................................................................................................................12061
3.7 Removing and installing tyre pressure sensor..............................................................................................................................................................................................................................................................................................................................................................................................................12062
4 Wheel alignment.................................................................................................................................................................................................................................................................................................................................................................................................................................................12065
4.1 General notes.............................................................................................................................................................................................................................................................................................................................................................................................................................................12065
4.2 Wheel alignment must be checked:..........................................................................................................................................................................................................................................................................................................................................................................................................................12066
4.3 Explanatory notes on production control numbers (PR Nos.).................................................................................................................................................................................................................................................................................................................................................................................................12067
4.4 Preparations required before calibration/adjustment of driver assist systems..............................................................................................................................................................................................................................................................................................................................................................................12068
4.5 Wheel alignment specifications............................................................................................................................................................................................................................................................................................................................................................................................................................12069
4.6 Test requirements for wheel alignment.....................................................................................................................................................................................................................................................................................................................................................................................................................12072
4.7 Preparations for measurement..............................................................................................................................................................................................................................................................................................................................................................................................................................12073
4.8 Sequence of operations for checking and adjusting wheel alignment.........................................................................................................................................................................................................................................................................................................................................................................................12074
4.9 Checking centre position of steering rack (mechanical method).............................................................................................................................................................................................................................................................................................................................................................................................12075
4.10 Wheel runout compensation................................................................................................................................................................................................................................................................................................................................................................................................................................12075
4.11 Checking full steering lock..............................................................................................................................................................................................................................................................................................................................................................................................................................12075
4.12 Checking camber at front wheels and centralising if necessary............................................................................................................................................................................................................................................................................................................................................................................................12076
4.13 Adjusting camber at rear wheels..........................................................................................................................................................................................................................................................................................................................................................................................................................12079
4.14 Adjusting toe setting at rear wheels.....................................................................................................................................................................................................................................................................................................................................................................................................................12079
4.15 Adjusting toe setting at front wheels....................................................................................................................................................................................................................................................................................................................................................................................................................12080
5 Dynamic steering................................................................................................................................................................................................................................................................................................................................................................................................................................................12081
5.1 General notes on dynamic steering.........................................................................................................................................................................................................................................................................................................................................................................................................................12081
5.2 Exploded view of dynamic steering.........................................................................................................................................................................................................................................................................................................................................................................................................................12082
5.3 Removing and installing active steering control unit -J792-...............................................................................................................................................................................................................................................................................................................................................................................................12083
5.4 Basic setting for dynamic steering........................................................................................................................................................................................................................................................................................................................................................................................................................12084
6 Adaptive Cruise Control (ACC)...................................................................................................................................................................................................................................................................................................................................................................................................................................12088
6.1 General information on ACC................................................................................................................................................................................................................................................................................................................................................................................................................................12088
6.2 Exploded view of sensor for adaptive cruise control -G550-................................................................................................................................................................................................................................................................................................................................................................................................12089
6.3 Removing and installing sensor for adaptive cruise control -G550-.........................................................................................................................................................................................................................................................................................................................................................................................12089
6.4 Renewing clip on adaptive cruise control unit (from Model Year 2012 onwards)..............................................................................................................................................................................................................................................................................................................................................................................12091
6.5 Preparing ACC setting device -VAS 6190- for adjustment procedure..........................................................................................................................................................................................................................................................................................................................................................................................12093
6.6 Adjustment procedure using ACC setting device -VAS 6190-..................................................................................................................................................................................................................................................................................................................................................................................................12095
6.7 Adjustment procedure using ACC setting device -VAS 6430-..................................................................................................................................................................................................................................................................................................................................................................................................12100
7 Lane departure warning (Audi lane assist).......................................................................................................................................................................................................................................................................................................................................................................................................................12106
7.1 General notes on lane departure warning function..........................................................................................................................................................................................................................................................................................................................................................................................................12106
7.2 Removing and installing lane departure warning control unit -J759- and backlight masking screen...........................................................................................................................................................................................................................................................................................................................................................12107
7.3 Calibration procedure.....................................................................................................................................................................................................................................................................................................................................................................................................................................12108
48 – Steering.........................................................................................................................................................................................................................................................................................................................................................................................................................................................12115
1 General notes...................................................................................................................................................................................................................................................................................................................................................................................................................................................12115
1.1 General information.......................................................................................................................................................................................................................................................................................................................................................................................................................................12115
1.2 Steering box..............................................................................................................................................................................................................................................................................................................................................................................................................................................12115
1.3 Gaskets and seals.........................................................................................................................................................................................................................................................................................................................................................................................................................................12116
1.4 Bolts and nuts............................................................................................................................................................................................................................................................................................................................................................................................................................................12116
1.5 Electrical components.....................................................................................................................................................................................................................................................................................................................................................................................................................................12116
2 Airbag steering wheel...........................................................................................................................................................................................................................................................................................................................................................................................................................................12117
2.1 Exploded view of airbag steering wheel....................................................................................................................................................................................................................................................................................................................................................................................................................12117
2.2 Removing and installing airbag steering wheel.............................................................................................................................................................................................................................................................................................................................................................................................................12117
3 Steering column.................................................................................................................................................................................................................................................................................................................................................................................................................................................12120
3.1 Exploded view of steering column..........................................................................................................................................................................................................................................................................................................................................................................................................................12120
3.2 Removing and installing intermediate steering shaft.......................................................................................................................................................................................................................................................................................................................................................................................................12121
3.3 Removing and installing steering column...................................................................................................................................................................................................................................................................................................................................................................................................................12124
3.4 Handling and transporting steering column.................................................................................................................................................................................................................................................................................................................................................................................................................12129
3.5 Checking steering column for damage.......................................................................................................................................................................................................................................................................................................................................................................................................................12130
3.6 Removing and installing electronic steering column lock control unit -J764-...............................................................................................................................................................................................................................................................................................................................................................................12130
3.7 Removing and installing safety lock for active steering (locking solenoid)................................................................................................................................................................................................................................................................................................................................................................................12133
4 Electromechanical power steering box............................................................................................................................................................................................................................................................................................................................................................................................................................12136
4.1 Exploded view of electromechanical power steering box with track rods.....................................................................................................................................................................................................................................................................................................................................................................................12136
4.2 Removing and installing electromechanical power steering box..............................................................................................................................................................................................................................................................................................................................................................................................12137
4.3 Centralising steering.....................................................................................................................................................................................................................................................................................................................................................................................................................................12140
4.4 Exploded view of electromechanical power steering box.....................................................................................................................................................................................................................................................................................................................................................................................................12140
4.5 Removing and installing track rod ball joint..............................................................................................................................................................................................................................................................................................................................................................................................................12143
4.6 Removing and installing track rod.........................................................................................................................................................................................................................................................................................................................................................................................................................12146
4.7 Renewing boot.............................................................................................................................................................................................................................................................................................................................................................................................................................................12150
5 Hydraulic power steering box....................................................................................................................................................................................................................................................................................................................................................................................................................................12156
5.1 Exploded view of hydraulic power steering box.............................................................................................................................................................................................................................................................................................................................................................................................................12156
5.2 Removing and installing hydraulic power steering box (LHD vehicles).......................................................................................................................................................................................................................................................................................................................................................................................12158
5.3 Centralising steering.....................................................................................................................................................................................................................................................................................................................................................................................................................................12163
5.4 Servicing hydraulic power steering box....................................................................................................................................................................................................................................................................................................................................................................................................................12163
5.5 Removing and installing servotronic solenoid valve -N119-.................................................................................................................................................................................................................................................................................................................................................................................................12166
5.6 Adjusting hydraulic power steering box....................................................................................................................................................................................................................................................................................................................................................................................................................12167
5.7 Removing and installing track rod ball joint..............................................................................................................................................................................................................................................................................................................................................................................................................12168
5.8 Removing and installing track rods........................................................................................................................................................................................................................................................................................................................................................................................................................12171
5.9 Removing and installing boot..............................................................................................................................................................................................................................................................................................................................................................................................................................12174
6 Checking fluid level, bleeding steering system and checking for leaks...........................................................................................................................................................................................................................................................................................................................................................................................12180
6.1 Checking fluid level of power steering....................................................................................................................................................................................................................................................................................................................................................................................................................12180
6.2 Bleeding steering system after repairs....................................................................................................................................................................................................................................................................................................................................................................................................................12181
6.3 Checking steering system for leaks........................................................................................................................................................................................................................................................................................................................................................................................................................12182
7 Power steering pump, hydraulic pipes and hoses, fluid reservoir (vehicles with 4-cylinder diesel engine)........................................................................................................................................................................................................................................................................................................................................................12183
7.1 Exploded view (vehicles with 4-cylinder diesel engine, vehicles with dynamic steering)....................................................................................................................................................................................................................................................................................................................................................................12183
7.2 Exploded view (vehicles with 4-cylinder diesel engine, vehicles without dynamic steering).................................................................................................................................................................................................................................................................................................................................................................12186
7.3 Exploded view of pipes and hoses (vehicles with 4-cylinder diesel engine, vehicles with and without dynamic steering).....................................................................................................................................................................................................................................................................................................................................12189
7.4 Checking delivery pressure of power steering pump (vehicles with 4-cylinder diesel engine, vehicles with and without dynamic steering)....................................................................................................................................................................................................................................................................................................................12192
7.5 Removing and installing power steering pump (vehicles with 4-cylinder diesel engine, vehicles with dynamic steering)......................................................................................................................................................................................................................................................................................................................................12197
7.6 Removing and installing power steering pump (vehicles with 4-cylinder diesel engine, vehicles without dynamic steering)...................................................................................................................................................................................................................................................................................................................................12204
8 Power steering pump, hydraulic pipes and hoses, fluid reservoir (vehicles with 4-cylinder TFSI engine)..........................................................................................................................................................................................................................................................................................................................................................12212
8.1 Exploded view (vehicles with 4-cylinder TFSI engine, vehicles with dynamic steering)......................................................................................................................................................................................................................................................................................................................................................................12212
8.2 Exploded view (vehicles with 4-cylinder TFSI engine, vehicles without dynamic steering)...................................................................................................................................................................................................................................................................................................................................................................12215
8.3 Exploded view of pipes and hoses (vehicles with 4-cylinder TFSI engine, vehicles with and without dynamic steering).......................................................................................................................................................................................................................................................................................................................................12218
8.4 Checking delivery pressure of power steering pump (vehicles with 4-cylinder TFSI engine, vehicles with and without dynamic steering)......................................................................................................................................................................................................................................................................................................................12221
8.5 Removing and installing power steering pump (vehicles with 4-cylinder TFSI engine, vehicles with dynamic steering)........................................................................................................................................................................................................................................................................................................................................12226
8.6 Removing and installing power steering pump (vehicles with 4-cylinder TFSI engine, vehicles without dynamic steering).....................................................................................................................................................................................................................................................................................................................................12234
9 Power steering pump, hydraulic pipes and hoses, fluid reservoir (vehicles with 6-cylinder diesel engine)........................................................................................................................................................................................................................................................................................................................................................12241
9.1 Exploded view (vehicles with 6-cylinder diesel engine, vehicles with dynamic steering)....................................................................................................................................................................................................................................................................................................................................................................12241
9.2 Exploded view (vehicles with 6-cylinder diesel engine, vehicles without dynamic steering).................................................................................................................................................................................................................................................................................................................................................................12244
9.3 Exploded view of pipes and hoses (vehicles with 6-cylinder diesel engine, vehicles with and without dynamic steering).....................................................................................................................................................................................................................................................................................................................................12247
9.4 Checking delivery pressure of power steering pump (vehicles with 6-cylinder diesel engine, vehicles with and without dynamic steering)....................................................................................................................................................................................................................................................................................................................12250
9.5 Removing and installing power steering pump (vehicles with 6-cylinder diesel engine, vehicles with dynamic steering)......................................................................................................................................................................................................................................................................................................................................12255
9.6 Removing and installing power steering pump (vehicles with 6-cylinder diesel engine, vehicles without dynamic steering)...................................................................................................................................................................................................................................................................................................................................12265
10 Power steering pump, hydraulic pipes and hoses, fluid reservoir (vehicles with 6-cylinder FSI engine)..........................................................................................................................................................................................................................................................................................................................................................12276
10.1 Exploded view (vehicles with 6-cylinder FSI engine, vehicles with dynamic steering)......................................................................................................................................................................................................................................................................................................................................................................12276
10.2 Exploded view (vehicles with 6-cylinder FSI engine, vehicles without dynamic steering)...................................................................................................................................................................................................................................................................................................................................................................12279
10.3 Exploded view of pipes and hoses (vehicles with 6-cylinder FSI engine, vehicles with and without dynamic steering).......................................................................................................................................................................................................................................................................................................................................12282
10.4 Checking delivery pressure of power steering pump (vehicles with 6-cylinder FSI engine, vehicles with and without dynamic steering)......................................................................................................................................................................................................................................................................................................................12284
10.5 Removing and installing power steering pump (vehicles with 6-cylinder FSI engine, vehicles with dynamic steering)........................................................................................................................................................................................................................................................................................................................................12290
10.6 Removing and installing power steering pump (vehicles with 6-cylinder FSI engine, vehicles without dynamic steering).....................................................................................................................................................................................................................................................................................................................................12301
11 Power steering pump, hydraulic pipes and hoses, fluid reservoir (vehicles with 6-cylinder TFSI engine).........................................................................................................................................................................................................................................................................................................................................................12312
11.1 Exploded view (vehicles with 6-cylinder TFSI engine, vehicles with dynamic steering).....................................................................................................................................................................................................................................................................................................................................................................12312
11.2 Exploded view (vehicles with 6-cylinder TFSI engine, vehicles without dynamic steering)..................................................................................................................................................................................................................................................................................................................................................................12315
11.3 Exploded view of pipes and hoses (vehicles with 6-cylinder TFSI engine, vehicles with and without dynamic steering)......................................................................................................................................................................................................................................................................................................................................12318
11.4 Checking delivery pressure of power steering pump (vehicles with 6-cylinder TFSI engine, vehicles with and without dynamic steering).....................................................................................................................................................................................................................................................................................................................12321
11.5 Removing and installing power steering pump (vehicles with 6-cylinder TFSI engine, vehicles with dynamic steering).......................................................................................................................................................................................................................................................................................................................................12326
11.6 Removing and installing power steering pump (vehicles with 6-cylinder TFSI engine, vehicles without dynamic steering)....................................................................................................................................................................................................................................................................................................................................12337
12 Power steering pump, hydraulic pipes and hoses, fluid reservoir (vehicles with 8-cylinder FSI engine)..........................................................................................................................................................................................................................................................................................................................................................12348
12.1 Exploded view (vehicles with 8-cylinder FSI engine, vehicles with dynamic steering)......................................................................................................................................................................................................................................................................................................................................................................12348
12.2 Exploded view (vehicles with 8-cylinder FSI engine, vehicles without dynamic steering)...................................................................................................................................................................................................................................................................................................................................................................12351
12.3 Exploded view of pipes and hoses (vehicles with 8-cylinder FSI engine, vehicles with and without dynamic steering).......................................................................................................................................................................................................................................................................................................................................12354
12.4 Checking delivery pressure of power steering pump (vehicles with 8-cylinder FSI engine, vehicles with and without dynamic steering)......................................................................................................................................................................................................................................................................................................................12357
12.5 Removing and installing power steering pump (vehicles with 8-cylinder FSI engine, vehicles with dynamic steering)........................................................................................................................................................................................................................................................................................................................................12361
12.6 Removing and installing power steering pump (vehicles with 8-cylinder FSI engine, vehicles without dynamic steering).....................................................................................................................................................................................................................................................................................................................................12367
13 Removing and installing hydraulic fluid cooler.................................................................................................................................................................................................................................................................................................................................................................................................................12374
13.1 Removing and installing hydraulic fluid cooler (vehicles with dynamic steering and vehicles with 8-cylinder FSI engine)..................................................................................................................................................................................................................................................................................................................................12374
13.2 Removing and installing hydraulic fluid cooler (RS 5 vehicles)...........................................................................................................................................................................................................................................................................................................................................................................................12376
14 Installation position of hoses.................................................................................................................................................................................................................................................................................................................................................................................................................................12379
14.1 Installation position of hoses on fluid reservoir, hydraulic fluid cooler and return line................................................................................................................................................................................................................................................................................................................................................................12379
Schematics................................................................................................................................................................................................................................................................................................................................................................................................................................................................12380
001 -
Basic equipment................................................................................................................................................................................................................................................................................................................................................................................................................................................12380
1.
Basic equipment...............................................................................................................................................................................................................................................................................................................................................................................................................................................12380
2. Entry and start authorisation switch, Fuse 6 on fuse holder D..................................................................................................................................................................................................................................................................................................................................................................................................12381
3. Control unit in dash panel insert, Radio controlled clock receiver, Radio controlled clock.....................................................................................................................................................................................................................................................................................................................................................................12382
4. Fuel gauge sender, Fuel system pressurisation pump, Control unit in dash panel insert..........................................................................................................................................................................................................................................................................................................................................................................12383
5. Steering column electronics control unit.......................................................................................................................................................................................................................................................................................................................................................................................................................12384
6. Turn signal switch, Cruise control system switch, Steering column electronics control unit.....................................................................................................................................................................................................................................................................................................................................................................12385
7. Intermittent wiper switch, Start/Stop operation button, Onboard supply control unit, Steering column electronics control unit, Control unit for electronic steering column lock................................................................................................................................................................................................................................................................................12386
8. Bonnet contact switch, Treble horn, Bass horn, Horn relay, Onboard supply control unit.........................................................................................................................................................................................................................................................................................................................................................................12387
9. Rain and light sensor, Wiper motor control unit, Onboard supply control unit...................................................................................................................................................................................................................................................................................................................................................................................12388
10. Gear detector switch, Front left brake pad wear sender, Onboard supply control unit, Headlight washer system pump, Left washer jet heater element, Right washer jet heater element............................................................................................................................................................................................................................................................................12389
11. Brake fluid level warning contact, Ambient temperature sensor, Coolant shortage indicator sender, Windscreen washer fluid level sender, Onboard supply control unit...........................................................................................................................................................................................................................................................................................12390
12. Switch module for driving mode selection, Onboard supply control unit.........................................................................................................................................................................................................................................................................................................................................................................................12391
13. Light switch, Hazard warning lights button, Onboard supply control unit.......................................................................................................................................................................................................................................................................................................................................................................................12392
14. Onboard supply control unit, Front left headlight.............................................................................................................................................................................................................................................................................................................................................................................................................12393
15. Onboard supply control unit, Front right headlight............................................................................................................................................................................................................................................................................................................................................................................................................12394
16. Rear left reading light button, Onboard supply control unit, Vanity mirror light bulb, Front interior light, Rear right interior light........................................................................................................................................................................................................................................................................................................................12395
17. Key operated switch to deactivate front passenger side airbag, Valet parking button, Onboard supply control unit, Valet parking warning lamp..................................................................................................................................................................................................................................................................................................................12396
18. Glove compartment light switch, Onboard supply control unit, Front left footwell illumination bulb, Front right footwell illumination bulb, Glove compartment light...........................................................................................................................................................................................................................................................................................12397
19. Onboard supply control unit, 12 V socket......................................................................................................................................................................................................................................................................................................................................................................................................................12398
20. Adaptive cruise control unit, Onboard supply control unit.....................................................................................................................................................................................................................................................................................................................................................................................................12399
21. Rear roller blind switch, TCS and ESP button, Parking aid button, Onboard supply control unit.................................................................................................................................................................................................................................................................................................................................................................12400
22. Entry and start authorisation button, Onboard supply control unit.............................................................................................................................................................................................................................................................................................................................................................................................12401
23. Entry and start authorisation button, Contact sensor for front left exterior door handle, Contact sensor for front right exterior door handle, Convenience system central control unit, Left aerial for entry and start authorisation.........................................................................................................................................................................................................................12402
24. Convenience system central control unit, Left tail light, Left tail light 2, Luggage compartment light........................................................................................................................................................................................................................................................................................................................................................12403
25. Convenience system central control unit, Rear lid central locking motor.......................................................................................................................................................................................................................................................................................................................................................................................12404
26. Convenience system central control unit, Right tail light, Right tail light 2.................................................................................................................................................................................................................................................................................................................................................................................12405
27. Button 1 for tilting roof, Sliding sunroof adjustment control unit, Convenience system central control unit, Sliding sunroof motor............................................................................................................................................................................................................................................................................................................................12406
28. Anti-theft alarm sensor, Alarm horn, Convenience system central control unit..................................................................................................................................................................................................................................................................................................................................................................................12407
29. Clutch pedal switch, Convenience system central control unit..................................................................................................................................................................................................................................................................................................................................................................................................12408
30. Brake light switch, Convenience system central control unit...................................................................................................................................................................................................................................................................................................................................................................................................12409
31. Convenience system central control unit.......................................................................................................................................................................................................................................................................................................................................................................................................................12410
32. Convenience system central control unit.......................................................................................................................................................................................................................................................................................................................................................................................................................12411
33. Convenience system central control unit, Rear roller blind motor, Tank filler flap locking motor, Heated rear window..........................................................................................................................................................................................................................................................................................................................................12412
34. Cigarette lighter, 12 V socket 2, 12 V socket 3...............................................................................................................................................................................................................................................................................................................................................................................................................12413
002 -
Convenience system.............................................................................................................................................................................................................................................................................................................................................................................................................................................12414
1.
Convenience system............................................................................................................................................................................................................................................................................................................................................................................................................................................12414
2. Entry and start authorisation button, Convenience system central control unit, Luggage compartment aerial for entry and start system, Interior aerial 1 for entry and start system.............................................................................................................................................................................................................................................................................12415
3. Anti-theft alarm sensor, Alarm horn, Convenience system central control unit, Aerial amplifier 3...............................................................................................................................................................................................................................................................................................................................................................12416
4. Contact sensor for front left exterior door handle, Contact sensor for front right exterior door handle, Convenience system central control unit, Left aerial for entry and start authorisation................................................................................................................................................................................................................................................................12417
5. Contact sensor for rear left exterior door handle, Contact sensor for rear right exterior door handle, Convenience system central control unit.................................................................................................................................................................................................................................................................................................................12418
6. Window aerial suppression filter, Heated rear window relay, Convenience system central control unit, Heated rear window single fuse, Heated rear window........................................................................................................................................................................................................................................................................................................12419
7. Contact switch in lock cylinder for rear lid, anti-theft alarm system and central locking system, Release button for rear lid lock cylinder, Convenience system central control unit, Rear lid central locking motor, Left number plate light, Right number plate light........................................................................................................................................................................................12420
8. Driver door control unit.......................................................................................................................................................................................................................................................................................................................................................................................................................................12421
9. Operating unit for window regulator in driver door, Driver door control unit, Driver side window regulator motor...............................................................................................................................................................................................................................................................................................................................................12422
10. Driver side central locking lock unit, Driver door control unit...............................................................................................................................................................................................................................................................................................................................................................................................12423
11. Driver side central locking lock unit, Driver door control unit...............................................................................................................................................................................................................................................................................................................................................................................................12424
12. Driver seat memory operating unit, Driver side interior locking switch, Rear lid remote release switch, Driver door control unit, Driver door opener illumination bulb, Driver side door warning lamp, Front left entry light.................................................................................................................................................................................................................................12425
13. Driver seat memory operating unit, Driver door control unit...................................................................................................................................................................................................................................................................................................................................................................................................12426
14. Mirror adjustment switch, Mirror adjustment changeover switch, Adjustment switch for mirror with fold-in feature, Interior monitoring switch, Alarm system off switch, Driver door control unit, Central locking SAFELOCK function warning lamp...............................................................................................................................................................................................................12427
15. Potentiometer for horizontal adjustment of driver side mirror, Potentiometer for vertical adjustment of driver side mirror, Driver door control unit, Driver side mirror adjustment motor, Driver side fold-in mirror motor, Driver side mirror adjustment motor..............................................................................................................................................................................................12428
16. Driver door control unit, Lane change assist warning lamp in driver side exterior mirror, Driver side turn signal repeater bulb, Driver side entry light in exterior mirror, Driver side automatic anti-dazzle exterior mirror, Heated exterior mirror on d
iver side.........................................................................................................................................................................................12429
17. Front passenger door control unit.............................................................................................................................................................................................................................................................................................................................................................................................................................12430
18. Front passenger side central locking lock unit, Front passenger door control unit.............................................................................................................................................................................................................................................................................................................................................................................12431
19. Window regulator switch in front passenger door, Front passenger side interior locking switch, Front passenger door control unit..............................................................................................................................................................................................................................................................................................................................12432
20. Front passenger door control unit, Front passenger door opener illumination bulb, Front passenger side window regulator motor, Front right entry light, Front passenger side door warning lamp................................................................................................................................................................................................................................................................12433
21. Potentiometer for horizontal adjustment of front passenger side mirror, Potentiometer for vertical adjustment of front passenger side mirror, Front passenger door control unit, Front passenger side mirror adjustment motor, Front passenger side fold-in mirror motor, Front passenger side mirror adjustment motor........................................................................................................................................12434
22. Front passenger door control unit, Lane change assist warning lamp in front passenger side exterior mirror, Front passenger side turn signal repeater bulb, Front passenger side entry light in exterior mirror, Front passenger side automatic anti-dazzle exterior mirror, Heated exterior mirror on front passenger side...................................................................................................................................12435
23. Rear left door control unit...................................................................................................................................................................................................................................................................................................................................................................................................................................12436
24. Rear left central locking lock unit, Rear left door control unit..............................................................................................................................................................................................................................................................................................................................................................................................12437
25. Rear left window regulator switch, in door, Rear left interior locking switch, Rear left door control unit, Rear left window regulator motor..................................................................................................................................................................................................................................................................................................................12438
26. Rear left door control unit, Rear left door opener illumination bulb, Rear left entry light, Rear left door warning lamp......................................................................................................................................................................................................................................................................................................................................12439
27. Rear right door control unit..................................................................................................................................................................................................................................................................................................................................................................................................................................12440
28. Rear right central locking lock unit, Rear right door control unit............................................................................................................................................................................................................................................................................................................................................................................................12441
29. Rear right window regulator switch, in door, Rear right interior locking switch, Rear right door control unit, Rear right window regulator motor..............................................................................................................................................................................................................................................................................................................12442
30. Rear right door control unit, Rear right door opener illumination bulb, Rear right entry light, Rear right door warning lamp..................................................................................................................................................................................................................................................................................................................................12443
003 -
Fuse assignment................................................................................................................................................................................................................................................................................................................................................................................................................................................12444
1.
Fuse assignment...............................................................................................................................................................................................................................................................................................................................................................................................................................................12444
2. Battery, Battery monitor control unit, Fuse 1 in fuse holder A.................................................................................................................................................................................................................................................................................................................................................................................................12445
3. Fuse 2 in fuse holder A, Fuse 3 in fuse holder A...............................................................................................................................................................................................................................................................................................................................................................................................................12446
4. Battery isolation igniter, Terminal 30 wiring junction 2, Jump start socket....................................................................................................................................................................................................................................................................................................................................................................................12447
5. Starter, Alternator, Terminal 30 wiring junction 2, Jump start socket..........................................................................................................................................................................................................................................................................................................................................................................................12448
6. Starter motor relay, Starter motor relay 2.....................................................................................................................................................................................................................................................................................................................................................................................................................12449
7. Fuse holder B, Fuse carrier 1..................................................................................................................................................................................................................................................................................................................................................................................................................................12450
8. Fuse holder B, Fuse carrier 1..................................................................................................................................................................................................................................................................................................................................................................................................................................12451
9. Fuse holder C, Fuse carrier 1..................................................................................................................................................................................................................................................................................................................................................................................................................................12452
10. Fuse holder C, Fuse carrier 1.................................................................................................................................................................................................................................................................................................................................................................................................................................12453
11. Fuse holder C, Fuse carrier 1.................................................................................................................................................................................................................................................................................................................................................................................................................................12454
12. Fuse holder C, Fuse carrier 2.................................................................................................................................................................................................................................................................................................................................................................................................................................12455
13. Fuse holder C, Fuse carrier 2.................................................................................................................................................................................................................................................................................................................................................................................................................................12456
14. Fuse holder C, Fuse carrier 2.................................................................................................................................................................................................................................................................................................................................................................................................................................12457
15. Fuse holder C, Fuse carrier 3.................................................................................................................................................................................................................................................................................................................................................................................................................................12458
16. Fuse holder C, Fuse carrier 3.................................................................................................................................................................................................................................................................................................................................................................................................................................12459
17. Fuse holder D, Fuse carrier 1.................................................................................................................................................................................................................................................................................................................................................................................................................................12460
18. Fuse holder D, Fuse carrier 1.................................................................................................................................................................................................................................................................................................................................................................................................................................12461
19. Fuse holder D, Fuse carrier 2.................................................................................................................................................................................................................................................................................................................................................................................................................................12462
20. Fuse holder D, Fuse carrier 2.................................................................................................................................................................................................................................................................................................................................................................................................................................12463
21. Fuse holder D, Fuse carrier 2.................................................................................................................................................................................................................................................................................................................................................................................................................................12464
22. Fuse holder F, Fuse carrier 1.................................................................................................................................................................................................................................................................................................................................................................................................................................12465
23. Fuse holder F, Fuse carrier 2.................................................................................................................................................................................................................................................................................................................................................................................................................................12466
24. Fuse holder F, Fuse carrier 2.................................................................................................................................................................................................................................................................................................................................................................................................................................12467
25. Fuse carrier 3................................................................................................................................................................................................................................................................................................................................................................................................................................................12468
26. Fuse holder F, Fuse carrier 3.................................................................................................................................................................................................................................................................................................................................................................................................................................12469
27. Fuse holder F, Fuse carrier 3.................................................................................................................................................................................................................................................................................................................................................................................................................................12470
28. Fuse holder F, Fuse carrier 3.................................................................................................................................................................................................................................................................................................................................................................................................................................12471
29. Fuse holder F, Fuse carrier 4.................................................................................................................................................................................................................................................................................................................................................................................................................................12472
30. Fuse holder F, Fuse carrier 4.................................................................................................................................................................................................................................................................................................................................................................................................................................12473
31. Fuse holder F, Fuse carrier 4.................................................................................................................................................................................................................................................................................................................................................................................................................................12474
004 -
CAN separating connector.......................................................................................................................................................................................................................................................................................................................................................................................................................................12475
1.
CAN separating connector......................................................................................................................................................................................................................................................................................................................................................................................................................................12475
2. ABS control unit, Power steering control unit, Active steering control unit....................................................................................................................................................................................................................................................................................................................................................................................12476
3. Digital sound package control unit, Telephone transmitter and receiver unit....................................................................................................................................................................................................................................................................................................................................................................................12477
4. Driver door control unit, Onboard supply control unit..........................................................................................................................................................................................................................................................................................................................................................................................................12478
5. ...............................................................................................................................................................................................................................................................................................................................................................................................................................................................12479
6. Control unit in dash panel insert, Auxiliary heater control unit, Steering column electronics control unit, Data bus diagnostic interface, Control unit for electromechanical parking brake....................................................................................................................................................................................................................................................................12480
7. Data bus diagnostic interface, Radio, Connection for external audio sources....................................................................................................................................................................................................................................................................................................................................................................................12481
8. Climatronic control unit, Front passenger door control unit, Steering column electronics control unit, Data bus diagnostic interface...........................................................................................................................................................................................................................................................................................................................12482
9. ...............................................................................................................................................................................................................................................................................................................................................................................................................................................................12483
005 -
multitronic 0AW (continuously variable automatic transmission).................................................................................................................................................................................................................................................................................................................................................................................................12484
1.
multitronic 0AW (continuously variable automatic transmission)................................................................................................................................................................................................................................................................................................................................................................................................12484
2. Automatic gearbox control unit, Convenience system central control unit, Engine control unit...................................................................................................................................................................................................................................................................................................................................................................12485
3. Automatic gearbox control unit, Data bus diagnostic interface, Engine control unit.............................................................................................................................................................................................................................................................................................................................................................................12486
4. Automatic gearbox control unit, Onboard supply control unit, Selector lever sensors control unit...............................................................................................................................................................................................................................................................................................................................................................12487
5. Gear selector position P switch, Automatic gearbox control unit, Selector lever lock solenoid..................................................................................................................................................................................................................................................................................................................................................................12488
006 -
6-speed automatic gearbox with Tiptronic.......................................................................................................................................................................................................................................................................................................................................................................................................................12489
1.
6-speed automatic gearbox with Tiptronic......................................................................................................................................................................................................................................................................................................................................................................................................................12489
2. Automatic gearbox control unit, Convenience system central control unit, Engine control unit...................................................................................................................................................................................................................................................................................................................................................................12490
3. Automatic gearbox control unit, Data bus diagnostic interface, Engine control unit.............................................................................................................................................................................................................................................................................................................................................................................12491
4. Automatic gearbox control unit, Onboard supply control unit, Selector lever sensors control unit...............................................................................................................................................................................................................................................................................................................................................................12492
5. Gear selector position P switch, Automatic gearbox control unit, Selector lever lock solenoid..................................................................................................................................................................................................................................................................................................................................................................12493
007 -
Preparation for mobile telephone (MOST bus) - USA..............................................................................................................................................................................................................................................................................................................................................................................................................12494
1.
Preparation for mobile telephone (MOST bus) - USA.............................................................................................................................................................................................................................................................................................................................................................................................................12494
2. Telephone transmitter and receiver unit, Telephone microphone, Aerial for Bluetooth, Microphone unit in front roof module......................................................................................................................................................................................................................................................................................................................................12495
3. Telephone transmitter and receiver unit, Radio, telephone and navigation system aerial, Telephone bracket......................................................................................................................................................................................................................................................................................................................................................12496
008 -
6-cylinder diesel engine , CAMA,CAMB,CAPA......................................................................................................................................................................................................................................................................................................................................................................................................................12497
1.
6-cylinder diesel engine , CAMA,CAMB,CAPA.....................................................................................................................................................................................................................................................................................................................................................................................................................12497
2. Battery, Terminal 15 voltage supply relay......................................................................................................................................................................................................................................................................................................................................................................................................................12498
3. Battery isolation igniter, Jump start socket...................................................................................................................................................................................................................................................................................................................................................................................................................12499
4. Starter, Alternator, Voltage regulator, Terminal 30 wiring junction 2, Jump start socket.......................................................................................................................................................................................................................................................................................................................................................................12500
5. Fuel pump relay, Terminal 30 voltage supply relay, Engine control unit.........................................................................................................................................................................................................................................................................................................................................................................................12501
6. Starter motor relay, Engine control unit, Starter motor relay 2................................................................................................................................................................................................................................................................................................................................................................................................12502
7. Automatic glow period control unit, Engine control unit........................................................................................................................................................................................................................................................................................................................................................................................................12503
8. Oil level and oil temperature sender, Engine control unit......................................................................................................................................................................................................................................................................................................................................................................................................12504
9. Throttle valve module, Engine control unit, Left electrohydraulic engine mounting solenoid valve, Right electrohydraulic engine mounting solenoid valve........................................................................................................................................................................................................................................................................................................12505
10. Low heat output relay, Engine control unit, Auxiliary air heater element......................................................................................................................................................................................................................................................................................................................................................................................12506
11. Engine speed sender, Hall sender, Engine control unit.........................................................................................................................................................................................................................................................................................................................................................................................................12507
12. Accelerator position sender, Accelerator position sender 2, Engine control unit...............................................................................................................................................................................................................................................................................................................................................................................12508
13. Engine control unit, Intake manifold flap motor, Intake manifold flap 2 motor.................................................................................................................................................................................................................................................................................................................................................................................12509
14. Charge pressure sender, Intake air temperature sender, Fuel pressure sender, Engine control unit, Exhaust gas recirculation control motor.....................................................................................................................................................................................................................................................................................................................12510
15. Exhaust gas pressure sensor 1, Engine control unit, Turbocharger 1 control unit...............................................................................................................................................................................................................................................................................................................................................................................12511
16. Air mass meter, Engine control unit...........................................................................................................................................................................................................................................................................................................................................................................................................................12512
17. Coolant temperature sender, Engine control unit...............................................................................................................................................................................................................................................................................................................................................................................................................12513
18. Lambda probe, Engine control unit.............................................................................................................................................................................................................................................................................................................................................................................................................................12514
19. Engine control unit, Injector, cylinder 1, Injector, cylinder 6...............................................................................................................................................................................................................................................................................................................................................................................................12515
20. Clutch position sender, Engine control unit...................................................................................................................................................................................................................................................................................................................................................................................................................12516
21. Brake light switch, Engine control unit, Supplementary fuel pump..............................................................................................................................................................................................................................................................................................................................................................................................12517
22. Engine control unit...........................................................................................................................................................................................................................................................................................................................................................................................................................................12518
23. Control unit in dash panel insert, Data bus diagnostic interface..............................................................................................................................................................................................................................................................................................................................................................................................12519
24. Fuel gauge sender, Fuel system pressurisation pump, Fuel gauge sender 2, Control unit in dash panel insert....................................................................................................................................................................................................................................................................................................................................................12520
25. Gear detector switch, Onboard supply control unit, Air conditioner compressor regulating valve................................................................................................................................................................................................................................................................................................................................................................12521
009 -
4.2l petrol engine , CAUA......................................................................................................................................................................................................................................................................................................................................................................................................................................12522
1.
4.2l petrol engine , CAUA.....................................................................................................................................................................................................................................................................................................................................................................................................................................12522
2. Battery, Terminal 15 voltage supply relay, Battery monitor control unit........................................................................................................................................................................................................................................................................................................................................................................................12523
3. Battery isolation igniter, Jump start socket...................................................................................................................................................................................................................................................................................................................................................................................................................12524
4. Starter, Alternator, Voltage regulator, Terminal 30 wiring junction 2, Jump start socket.......................................................................................................................................................................................................................................................................................................................................................................12525
5. Main relay, Engine control unit, Engine component current supply relay.........................................................................................................................................................................................................................................................................................................................................................................................12526
6. Starter motor relay, Engine control unit, Starter motor relay 2................................................................................................................................................................................................................................................................................................................................................................................................12527
7. Engine control unit............................................................................................................................................................................................................................................................................................................................................................................................................................................12528
8. Engine control unit, Activated charcoal filter solenoid valve 1, Left electrohydraulic engine mounting solenoid valve, Fuel metering valve, Variable intake manifold changeover valve, Fuel metering valve 2, Fuel system diagnostic pump......................................................................................................................................................................................................................12529
9. Air mass meter, Secondary air pump relay, Engine control unit, Right electrohydraulic engine mounting solenoid valve, Secondary air pump motor.................................................................................................................................................................................................................................................................................................................12530
10. Continued coolant circulation relay, Engine control unit, Camshaft control valve 1, Camshaft control valve 2, Exhaust camshaft control valve 1, Exhaust camshaft control valve 2, Continued coolant circulation pump..........................................................................................................................................................................................................................................12531
11. Map-controlled engine cooling system thermostat, Engine control unit, Intake manifold flap motor, Variable intake manifold motor..............................................................................................................................................................................................................................................................................................................................12532
12. Oil level and oil temperature sender, Brake servo relay, Engine control unit, Vacuum pump for brakes..........................................................................................................................................................................................................................................................................................................................................................12533
13. Engine control unit, Ignition coil 1 with output stage, Ignition coil 2 with output stage, Ignition coil 3 with output stage, Ignition coil 4 with output stage...............................................................................................................................................................................................................................................................................................12534
14. Engine control unit, Ignition coil 5 with output stage, Ignition coil 6 with output stage, Ignition coil 7 with output stage, Ignition coil 8 with output stage...............................................................................................................................................................................................................................................................................................12535
15. Knock sensor 1, Knock sensor 2, Knock sensor 3, Throttle valve module, Engine control unit....................................................................................................................................................................................................................................................................................................................................................................12536
16. Engine speed sender, Hall sender, Knock sensor 4, Hall sender 3, Engine control unit..........................................................................................................................................................................................................................................................................................................................................................................12537
17. Coolant temperature sender, Fuel pressure sender, Intake manifold flap potentiometer, Intake manifold flap potentiometer 2, Engine control unit...............................................................................................................................................................................................................................................................................................................12538
18. Accelerator position sender, Engine control unit..............................................................................................................................................................................................................................................................................................................................................................................................................12539
19. Hall sender 2, Brake servo pressure sensor, Hall sender 4, Fuel pressure sender for low-pressure, Engine control unit.........................................................................................................................................................................................................................................................................................................................................12540
20. Lambda probe, Lambda probe 2, Engine control unit.............................................................................................................................................................................................................................................................................................................................................................................................................12541
21. Lambda probe after catalytic converter, Lambda probe 2 after catalytic converter, Engine control unit.........................................................................................................................................................................................................................................................................................................................................................12542
22. Engine control unit, Injector, cylinder 1, Injector, cylinder 2, Injector, cylinder 6, Injector, cylinder 8...................................................................................................................................................................................................................................................................................................................................................12543
23. Engine control unit, Injector, cylinder 3, Injector, cylinder 4, Injector, cylinder 5, Injector, cylinder 7...................................................................................................................................................................................................................................................................................................................................................12544
24. Clutch position sender, Engine control unit...................................................................................................................................................................................................................................................................................................................................................................................................................12545
25. Brake light switch, Engine control unit.......................................................................................................................................................................................................................................................................................................................................................................................................................12546
26. Automatic gearbox control unit, Data bus diagnostic interface, Engine control unit............................................................................................................................................................................................................................................................................................................................................................................12547
27. Control unit in dash panel insert, Data bus diagnostic interface..............................................................................................................................................................................................................................................................................................................................................................................................12548
28. Fuel gauge sender, Fuel system pressurisation pump, Fuel gauge sender 2, Control unit in dash panel insert, Fuel pump control unit............................................................................................................................................................................................................................................................................................................................12549
29. Oil pressure switch, Gear detector switch, Coolant shortage indicator sender, Onboard supply control unit, Servotronic solenoid valve, Air conditioner compressor regulating valve............................................................................................................................................................................................................................................................................12550
010 -
3.2l petrol engine , CALA......................................................................................................................................................................................................................................................................................................................................................................................................................................12551
1.
3.2l petrol engine , CALA.....................................................................................................................................................................................................................................................................................................................................................................................................................................12551
2. Battery, Terminal 15 voltage supply relay......................................................................................................................................................................................................................................................................................................................................................................................................................12552
3. Battery isolation igniter, Terminal 30 wiring junction 2, Jump start socket....................................................................................................................................................................................................................................................................................................................................................................................12553
4. Starter, Alternator, Voltage regulator, Jump start socket......................................................................................................................................................................................................................................................................................................................................................................................................12554
5. Main relay, Engine control unit, Engine component current supply relay.........................................................................................................................................................................................................................................................................................................................................................................................12555
6. Starter motor relay, Engine control unit, Starter motor relay 2, Fuse carrier 1................................................................................................................................................................................................................................................................................................................................................................................12556
7. Oil level and oil temperature sender, Engine control unit, Fuse carrier 1......................................................................................................................................................................................................................................................................................................................................................................................12557
8. Engine control unit, Camshaft control valve 1, Exhaust camshaft control valve 1, Climatronic coolant shut-off valve, Continued coolant circulation pump........................................................................................................................................................................................................................................................................................................12558
9. Actuator 1 for camshaft adjustment, Engine control unit, Left electrohydraulic engine mounting solenoid valve, Exhaust camshaft control valve 2................................................................................................................................................................................................................................................................................................................12559
10. Actuator 6 for camshaft adjustment, Actuator 7 for camshaft adjustment, Actuator 8 for camshaft adjustment, Engine control unit...............................................................................................................................................................................................................................................................................................................................12560
11. Engine control unit, Activated charcoal filter solenoid valve 1, Variable intake manifold changeover valve, Fuel metering valve, Fuel system diagnostic pump..................................................................................................................................................................................................................................................................................................12561
12. Engine control unit, Secondary air inlet valve, Valve for oil pressure control, Secondary air pump motor......................................................................................................................................................................................................................................................................................................................................................12562
13. Engine control unit, Ignition coil 1 with output stage, Ignition coil 2 with output stage, Ignition coil 3 with output stage..................................................................................................................................................................................................................................................................................................................................12563
14. Engine control unit, Ignition coil 4 with output stage, Ignition coil 5 with output stage, Ignition coil 6 with output stage..................................................................................................................................................................................................................................................................................................................................12564
15. Knock sensor 1, Knock sensor 2, Engine control unit...........................................................................................................................................................................................................................................................................................................................................................................................................12565
16. Engine speed sender, Coolant temperature sender, Fuel pressure sender for low-pressure, Throttle valve module, Engine control unit............................................................................................................................................................................................................................................................................................................................12566
17. Hall sender, Intake air temperature sender, Fuel pressure sender, Engine control unit.........................................................................................................................................................................................................................................................................................................................................................................12567
18. Accelerator position sender, Hall sender 2, Accelerator position sender 2, Hall sender 3, Sender 1 for secondary air pressure, Engine control unit............................................................................................................................................................................................................................................................................................................12568
19. Oil pressure switch for reduced oil pressure, Hall sender 4, Variable intake manifold position sender, Engine control unit....................................................................................................................................................................................................................................................................................................................................12569
20. Engine control unit, Injector, cylinder 1, Injector, cylinder 2, Injector, cylinder 3, Injector, cylinder 4, Injector, cylinder 5, Injector, cylinder 6.......................................................................................................................................................................................................................................................................................................12570
21. Lambda probe, Lambda probe 2, Engine control unit.............................................................................................................................................................................................................................................................................................................................................................................................................12571
22. Lambda probe after catalytic converter, Lambda probe 2 after catalytic converter, Engine control unit.........................................................................................................................................................................................................................................................................................................................................................12572
23. Clutch position sender, Engine control unit...................................................................................................................................................................................................................................................................................................................................................................................................................12573
24. Brake light switch, Engine control unit.......................................................................................................................................................................................................................................................................................................................................................................................................................12574
25. Automatic gearbox control unit, Data bus diagnostic interface, Engine control unit............................................................................................................................................................................................................................................................................................................................................................................12575
26. Control unit in dash panel insert, Data bus diagnostic interface..............................................................................................................................................................................................................................................................................................................................................................................................12576
27. Fuel gauge sender, Fuel system pressurisation pump, Control unit in dash panel insert, Fuel pump control unit.................................................................................................................................................................................................................................................................................................................................................12577
28. Oil pressure switch, Coolant shortage indicator sender, Onboard supply control unit...........................................................................................................................................................................................................................................................................................................................................................................12578
29. Circulation pump relay, Coolant circulation pump..............................................................................................................................................................................................................................................................................................................................................................................................................12579
011 -
Data bus diagnostic interface and diagnostic connector.........................................................................................................................................................................................................................................................................................................................................................................................................12580
1.
Data bus diagnostic interface and diagnostic connector........................................................................................................................................................................................................................................................................................................................................................................................................12580
2. Data bus diagnostic interface..................................................................................................................................................................................................................................................................................................................................................................................................................................12581
3. Data bus diagnostic interface..................................................................................................................................................................................................................................................................................................................................................................................................................................12582
4. Data bus diagnostic interface..................................................................................................................................................................................................................................................................................................................................................................................................................................12583
012 -
1.8l petrol engine , CABD,CDHB.................................................................................................................................................................................................................................................................................................................................................................................................................................12584
1.
1.8l petrol engine , CABD,CDHB................................................................................................................................................................................................................................................................................................................................................................................................................................12584
2. Battery, Terminal 15 voltage supply relay, Battery monitor control unit........................................................................................................................................................................................................................................................................................................................................................................................12585
3. Battery isolation igniter, Jump start socket...................................................................................................................................................................................................................................................................................................................................................................................................................12586
4. Starter, Alternator, Voltage regulator, Suppression filter, Terminal 30 wiring junction 2, Jump start socket...................................................................................................................................................................................................................................................................................................................................................12587
5. Main relay, Engine control unit, Engine component current supply relay.........................................................................................................................................................................................................................................................................................................................................................................................12588
6. Starter motor relay, Engine control unit, Starter motor relay 2................................................................................................................................................................................................................................................................................................................................................................................................12589
7. Oil level and oil temperature sender, Engine control unit......................................................................................................................................................................................................................................................................................................................................................................................................12590
8. Engine control unit, Charge pressure control solenoid valve, Activated charcoal filter solenoid valve 1, Left electrohydraulic engine mounting solenoid valve, Camshaft control valve 1, Turbocharger air recirculation valve, Intake manifold flap valve, Valve for oil pressure control......................................................................................................................................................................12591
9. Additional coolant pump relay, Engine control unit, Climatronic coolant shut-off valve, Continued coolant circulation pump.....................................................................................................................................................................................................................................................................................................................................12592
10. Engine control unit, Ignition coil 1 with output stage, Ignition coil 2 with output stage, Ignition coil 3 with output stage, Ignition coil 4 with output stage...............................................................................................................................................................................................................................................................................................12593
11. Accelerator position sender, Accelerator position sender 2, Engine control unit...............................................................................................................................................................................................................................................................................................................................................................................12594
12. Engine speed sender, Hall sender, Knock sensor 1, Engine control unit.........................................................................................................................................................................................................................................................................................................................................................................................12595
13. Charge pressure sender, Fuel pressure sender, Intake manifold flap potentiometer, Throttle valve module, Engine control unit..................................................................................................................................................................................................................................................................................................................................12596
14. Oil pressure switch, Oil pressure switch for reduced oil pressure, Intake air temperature sender, Coolant temperature sender, Engine control unit.............................................................................................................................................................................................................................................................................................................12597
15. Air mass meter, Engine control unit, Fuel pressure regulating valve...........................................................................................................................................................................................................................................................................................................................................................................................12598
16. Engine control unit, Injector, cylinder 1, Injector, cylinder 2, Injector, cylinder 3, Injector, cylinder 4...................................................................................................................................................................................................................................................................................................................................................12599
17. Lambda probe, Lambda probe after catalytic converter, Engine control unit.....................................................................................................................................................................................................................................................................................................................................................................................12600
18. Clutch position sender, Engine control unit...................................................................................................................................................................................................................................................................................................................................................................................................................12601
19. Brake light switch, Steering column electronics control unit, Engine control unit.............................................................................................................................................................................................................................................................................................................................................................................12602
20. Automatic gearbox control unit, Data bus diagnostic interface, Engine control unit............................................................................................................................................................................................................................................................................................................................................................................12603
21. Control unit in dash panel insert, Data bus diagnostic interface..............................................................................................................................................................................................................................................................................................................................................................................................12604
22. Fuel gauge sender, Fuel system pressurisation pump, Control unit in dash panel insert, Fuel pump control unit.................................................................................................................................................................................................................................................................................................................................................12605
23. Gear detector switch, Coolant shortage indicator sender, Onboard supply control unit, Servotronic solenoid valve, Air conditioner compressor regulating valve.................................................................................................................................................................................................................................................................................................12606
013 -
Gas discharge headlights with automatic headlight range control................................................................................................................................................................................................................................................................................................................................................................................................12607
1.
Gas discharge headlights with automatic headlight range control...............................................................................................................................................................................................................................................................................................................................................................................................12607
2. Light switch, Rear left vehicle level sender, Headlight range control unit, Onboard supply control unit........................................................................................................................................................................................................................................................................................................................................................12608
3. Left gas discharge bulb control unit, Headlight range control unit, Onboard supply control unit, Left headlight range control motor, Left dip beam screen motor................................................................................................................................................................................................................................................................................................12609
4. Headlight range control unit, Onboard supply control unit, Left LED module for daytime running light and side light............................................................................................................................................................................................................................................................................................................................................12610
5. Right gas discharge bulb control unit, Headlight range control unit, Onboard supply control unit, Right gas discharge (xenon) bulb, Right headlight range control motor, Right dip beam screen motor...........................................................................................................................................................................................................................................................12611
6. Onboard supply control unit, Front right turn signal bulb......................................................................................................................................................................................................................................................................................................................................................................................................12612
014 -
400 W radiator fan for 4-cylinder and 6-cylinder petrol engines................................................................................................................................................................................................................................................................................................................................................................................................12613
1.
400 W radiator fan for 4-cylinder and 6-cylinder petrol engines...............................................................................................................................................................................................................................................................................................................................................................................................12613
2. Radiator fan control unit, Radiator fan........................................................................................................................................................................................................................................................................................................................................................................................................................12614
015 -
600 W radiator fan for 4-cylinder and 6-cylinder petrol engines................................................................................................................................................................................................................................................................................................................................................................................................12615
1.
600 W radiator fan for 4-cylinder and 6-cylinder petrol engines...............................................................................................................................................................................................................................................................................................................................................................................................12615
2. Radiator fan control unit, Radiator fan, Radiator fan 2........................................................................................................................................................................................................................................................................................................................................................................................................12616
016 -
400 W radiator fan for 4-cylinder and 6-cylinder diesel engines................................................................................................................................................................................................................................................................................................................................................................................................12617
1.
400 W radiator fan for 4-cylinder and 6-cylinder diesel engines...............................................................................................................................................................................................................................................................................................................................................................................................12617
2. Radiator fan control unit, Radiator fan........................................................................................................................................................................................................................................................................................................................................................................................................................12618
017 -
600 W radiator fan for 4-cylinder and 6-cylinder diesel engines................................................................................................................................................................................................................................................................................................................................................................................................12619
1.
600 W radiator fan for 4-cylinder and 6-cylinder diesel engines...............................................................................................................................................................................................................................................................................................................................................................................................12619
2. Radiator fan control unit, Radiator fan, Radiator fan 2........................................................................................................................................................................................................................................................................................................................................................................................................12620
018 -
800 W/1000 W radiator fan for 6-cylinder diesel engines........................................................................................................................................................................................................................................................................................................................................................................................................12621
1.
800 W/1000 W radiator fan for 6-cylinder diesel engines.......................................................................................................................................................................................................................................................................................................................................................................................................12621
2. Radiator fan control unit, Radiator fan control unit 2, Terminal 30 wiring junction 2, Radiator fan, Radiator fan 2............................................................................................................................................................................................................................................................................................................................................12622
019 -
800 W/1000 W radiator fan for 6-cylinder and 8-cylinder petrol engines.........................................................................................................................................................................................................................................................................................................................................................................................12623
1.
800 W/1000 W radiator fan for 6-cylinder and 8-cylinder petrol engines........................................................................................................................................................................................................................................................................................................................................................................................12623
2. Radiator fan control unit, Radiator fan control unit 2, Terminal 30 wiring junction 2, Radiator fan, Radiator fan 2............................................................................................................................................................................................................................................................................................................................................12624
020 -
Parking aid (PDC)..............................................................................................................................................................................................................................................................................................................................................................................................................................................12625
1.
Parking aid (PDC).............................................................................................................................................................................................................................................................................................................................................................................................................................................12625
2. Front left parking aid sender, Front parking aid warning buzzer, Park assist steering control unit.............................................................................................................................................................................................................................................................................................................................................................12626
3. Rear left parking aid sender, Rear right parking aid sender, Rear parking aid warning buzzer, Park assist steering control unit................................................................................................................................................................................................................................................................................................................................12627
4. Parking aid button, Park assist steering control unit..........................................................................................................................................................................................................................................................................................................................................................................................................12628
021 -
Airbag systems.................................................................................................................................................................................................................................................................................................................................................................................................................................................12629
1.
Airbag systems................................................................................................................................................................................................................................................................................................................................................................................................................................................12629
2. Airbag coil connector and return ring with slip ring, Airbag control unit, Driver side airbag igniter, Front passenger side airbag igniter 1, Front passenger side airbag igniter 2, Driver side airbag igniter 2..............................................................................................................................................................................................................................................12630
3. Airbag control unit, Driver side curtain airbag igniter, Front passenger side curtain airbag igniter, Battery isolation igniter................................................................................................................................................................................................................................................................................................................................12631
4. Driver side belt force limiter, Front passenger side belt force limiter, Airbag control unit, Driver seat belt tensioner igniter 1, Front passenger seat belt tensioner igniter 1, Rear belt tensioner igniter on driver side, Rear belt tensioner igniter o
front passenger side, Rear centre belt tensioner igniter.........................................................................................................................................12632
5. Side airbag crash sensor on driver side, Side airbag crash sensor on front passenger side, Rear side airbag crash sensor on driver side, Rear side airbag crash sensor on front passenger side, Front airbag crash sensor for driver side, Front airbag crash sensor for front passenger side, Airbag control unit.............................................................................................................................................12633
6. Airbag control unit, Side airbag igniter on driver side, Side airbag igniter on front passenger side, Rear side airbag igniter on driver side, Rear side airbag igniter on front passenger side................................................................................................................................................................................................................................................................12634
7. Key operated switch to deactivate front passenger side airbag, Airbag control unit, Front passenger side airbag deactivated warning lamp.......................................................................................................................................................................................................................................................................................................................12635
8. Driver side belt switch, Front passenger side belt switch, Seat occupied sensor, front passenger side, Driver side seat position sensor, Front passenger side seat position sensor, Airbag control unit........................................................................................................................................................................................................................................................12636
9. Front passenger side belt switch, Pressure sensor for seat occupied recognition, Seat belt force sensor for seat occupied recognition, Front passenger side seat position sensor, Airbag control unit, Seat occupied recognition control unit..................................................................................................................................................................................................................12637
10. Airbag control unit, Driver side knee airbag igniter, Front passenger side knee airbag igniter................................................................................................................................................................................................................................................................................................................................................................12638
11. Airbag control unit, Data bus diagnostic interface............................................................................................................................................................................................................................................................................................................................................................................................................12639
12. Control unit in dash panel insert, Data bus diagnostic interface, Airbag warning lamp.........................................................................................................................................................................................................................................................................................................................................................................12640
022 -
Reversing camera (Rear Assist).................................................................................................................................................................................................................................................................................................................................................................................................................................12641
1.
Reversing camera (Rear Assist)................................................................................................................................................................................................................................................................................................................................................................................................................................12641
2. Reversing camera system control unit, Reversing camera.........................................................................................................................................................................................................................................................................................................................................................................................................12642
3. Reversing camera system control unit, Control unit 1 for information electronics...............................................................................................................................................................................................................................................................................................................................................................................12643
023 -
Automatic adaptive suspension, adjustable dampers..............................................................................................................................................................................................................................................................................................................................................................................................................12644
1.
Automatic adaptive suspension, adjustable dampers.............................................................................................................................................................................................................................................................................................................................................................................................................12644
2. Electronically controlled damping control unit.................................................................................................................................................................................................................................................................................................................................................................................................................12645
3. Front left body acceleration sender, Front right body acceleration sender, Rear body acceleration sender, Electronically controlled damping control unit.......................................................................................................................................................................................................................................................................................................12646
4. Rear left vehicle level sender, Rear right vehicle level sender, Front left vehicle level sender, Front right vehicle level sender, Electronically controlled damping control unit.............................................................................................................................................................................................................................................................................12647
5. Electronically controlled damping control unit, Front left shock absorber damping adjustment valve, Front right shock absorber damping adjustment valve, Rear left shock absorber damping adjustment valve, Rear right shock absorber damping adjustment valve.................................................................................................................................................................................................12648
6. Electronically controlled damping control unit, Data bus diagnostic interface..................................................................................................................................................................................................................................................................................................................................................................................12649
7. Switch module for driving mode selection, Onboard supply control unit, Data bus diagnostic interface...........................................................................................................................................................................................................................................................................................................................................................12650
024 -
Electromechanical parking brake................................................................................................................................................................................................................................................................................................................................................................................................................................12651
1.
Electromechanical parking brake...............................................................................................................................................................................................................................................................................................................................................................................................................................12651
2. Control unit for electromechanical parking brake...............................................................................................................................................................................................................................................................................................................................................................................................................12652
3. Electromechanical parking brake button, Auto-hold button, ABS control unit, Control unit for electromechanical parking brake...................................................................................................................................................................................................................................................................................................................................12653
4. Control unit for electromechanical parking brake, Left parking brake motor, Right parking brake motor, Connection 2 (running gear/dash panel insert CAN bus, high), in main wiring harness, Connection 2 (running gear/dash panel insert CAN bus, low), in main wiring harness.................................................................................................................................................................................12654
025 -
Trailer coupling...............................................................................................................................................................................................................................................................................................................................................................................................................................................12655
1.
Trailer coupling..............................................................................................................................................................................................................................................................................................................................................................................................................................................12655
2. Terminal 15 voltage supply relay, Trailer detector control unit, Voltage stabiliser, Fuse carrier 2, Fuse carrier 4............................................................................................................................................................................................................................................................................................................................................12656
3. Trailer detector control unit..................................................................................................................................................................................................................................................................................................................................................................................................................................12657
4. Trailer detector control unit, Trailer socket..................................................................................................................................................................................................................................................................................................................................................................................................................12658
026 -
Gas discharge headlights (bi-xenon) with automatic headlight range control and cornering light.................................................................................................................................................................................................................................................................................................................................................................12659
1.
Gas discharge headlights (bi-xenon) with automatic headlight range control and cornering light................................................................................................................................................................................................................................................................................................................................................................12659
2. Control unit for cornering light and headlight range control...................................................................................................................................................................................................................................................................................................................................................................................................12660
3. Light switch, Rear left vehicle level sender, Onboard supply control unit, Control unit for cornering light and headlight range control........................................................................................................................................................................................................................................................................................................................12661
4. Onboard supply control unit, Output module for left headlight, Left gas discharge (xenon) bulb, Left headlight range control motor, Left dip beam screen motor, Left dynamic cornering light control motor.....................................................................................................................................................................................................................................................12662
5. Onboard supply control unit, Left LED module for daytime running light and side light, Front left turn signal bulb, Left parking light bulb....................................................................................................................................................................................................................................................................................................................12663
6. Right gas discharge bulb control unit, Onboard supply control unit, Output module for right headlight, Right gas discharge (xenon) bulb, Right headlight range control motor, Right dip beam screen motor, Right dynamic cornering light control motor.........................................................................................................................................................................................................12664
7. Onboard supply control unit, Front right turn signal bulb, Right parking light bulb............................................................................................................................................................................................................................................................................................................................................................................12665
027 -
Auxiliary heater...............................................................................................................................................................................................................................................................................................................................................................................................................................................12666
1.
Auxiliary heater..............................................................................................................................................................................................................................................................................................................................................................................................................................................12666
2. Auxiliary heater control unit, Circulation pump................................................................................................................................................................................................................................................................................................................................................................................................................12667
3. Auxiliary heater control unit, Remote control receiver for auxiliary heater, Auxiliary heater aerial...........................................................................................................................................................................................................................................................................................................................................................12668
4. Fuel gauge sender, Fuel system pressurisation pump.............................................................................................................................................................................................................................................................................................................................................................................................................12669
5. Fuel gauge sender, Fuel delivery unit, Fuel system pressurisation pump, Fuel gauge sender 2, Fuel pump control unit............................................................................................................................................................................................................................................................................................................................................12670
028 -
Garage door opener.............................................................................................................................................................................................................................................................................................................................................................................................................................................12671
1.
Garage door opener............................................................................................................................................................................................................................................................................................................................................................................................................................................12671
2. Garage door operating unit, Garage door operation control unit.................................................................................................................................................................................................................................................................................................................................................................................................12672
029 -
Seat heating...................................................................................................................................................................................................................................................................................................................................................................................................................................................12673
1.
Seat heating..................................................................................................................................................................................................................................................................................................................................................................................................................................................12673
2. Heated driver seat regulator, Heated front passenger seat regulator, Onboard supply control unit, Heated seat cushion for driver seat, Heated backrest for driver seat.........................................................................................................................................................................................................................................................................................12674
3. Onboard supply control unit, Heated seat cushion for front passenger seat, Heated backrest for front passenger seat............................................................................................................................................................................................................................................................................................................................................12675
4. Heated rear left seat switch with regulator, Onboard supply control unit, Heated bench seat cushion for rear left seat.........................................................................................................................................................................................................................................................................................................................................12676
5. Heated rear right seat switch with regulator, Heated bench seat cushion for rear right seat....................................................................................................................................................................................................................................................................................................................................................................12677
030 -
Front passenger seat with electrically adjustable lumbar support, seat ventilation and heating, 2-door vehicle.................................................................................................................................................................................................................................................................................................................................................12678
1.
Front passenger seat with electrically adjustable lumbar support, seat ventilation and heating, 2-door vehicle................................................................................................................................................................................................................................................................................................................................................12678
2. Front passenger seat adjustment with memory control unit, Rear right footwell light............................................................................................................................................................................................................................................................................................................................................................................12679
3. Front passenger seat adjustment operating unit, Front passenger seat adjustment with memory control unit, Front passenger seat longitudinal adjustment motor, Front passenger seat rake adjustment motor, Front passenger seat height adjustment motor.........................................................................................................................................................................................................12680
4. Front passenger seat adjustment with memory control unit, Front passenger seat backrest adjustment motor, Front passenger seat head restraint adjustment motor.................................................................................................................................................................................................................................................................................................12681
5. Front passenger seat backrest locking switch, Upright movement limit switch for front passenger seat backrest, Front passenger seat adjustment with memory control unit........................................................................................................................................................................................................................................................................................12682
6. Front right seat temperature sender, Front passenger seat adjustment with memory control unit, Heated seat cushion for front passenger seat, Heated backrest for front passenger seat..........................................................................................................................................................................................................................................................................12683
7. Front passenger seat adjustment with memory control unit, Front passenger seat backrest fan, Front passenger seat cushion fan..................................................................................................................................................................................................................................................................................................................................12684
8. Front passenger seat lumbar support adjustment switch..........................................................................................................................................................................................................................................................................................................................................................................................................12685
031 -
Driver seat with memory function, electrically adjustable lumbar support, seat ventilation and heating, 2-door vehicle.........................................................................................................................................................................................................................................................................................................................................12686
1.
Driver seat with memory function, electrically adjustable lumbar support, seat ventilation and heating, 2-door vehicle........................................................................................................................................................................................................................................................................................................................................12686
2. Seat and steering column adjustment control unit with memory, Rear left footwell light.........................................................................................................................................................................................................................................................................................................................................................................12687
3. Driver seat adjustment operating unit, Seat and steering column adjustment control unit with memory, Driver seat longitudinal adjustment motor, Driver seat rake adjustment motor, Driver seat height adjustment motor.........................................................................................................................................................................................................................................12688
4. Seat and steering column adjustment control unit with memory, Driver seat backrest adjustment motor, Driver seat head restraint adjustment motor...............................................................................................................................................................................................................................................................................................................12689
5. Driver seat backrest locking switch, Upright movement limit switch for driver seat backrest, Seat and steering column adjustment control unit with memory......................................................................................................................................................................................................................................................................................................12690
6. Front left seat temperature sender, Seat and steering column adjustment control unit with memory, Heated seat cushion for driver seat, Heated backrest for driver seat.........................................................................................................................................................................................................................................................................................12691
7. Seat and steering column adjustment control unit with memory, Driver seat backrest fan, Driver seat cushion fan................................................................................................................................................................................................................................................................................................................................................12692
8. Driver seat lumbar support adjustment switch...................................................................................................................................................................................................................................................................................................................................................................................................................12693
9. Driver seat memory operating unit, Emergency-off button, Driver door control unit..............................................................................................................................................................................................................................................................................................................................................................................12694
032 -
Electrically adjustable lumbar support on seat without electric adjustment.....................................................................................................................................................................................................................................................................................................................................................................................12695
1.
Electrically adjustable lumbar support on seat without electric adjustment....................................................................................................................................................................................................................................................................................................................................................................................12695
2. Driver seat lumbar support longitudinal adjustment motor, Driver seat lumbar support height adjustment motor, Rear left footwell light.........................................................................................................................................................................................................................................................................................................................12696
3. Front passenger seat lumbar support longitudinal adjustment motor, Front passenger seat lumbar support height adjustment motor, Rear right footwell light......................................................................................................................................................................................................................................................................................................12697
033 -
Multifunction steering wheel...................................................................................................................................................................................................................................................................................................................................................................................................................................12698
1.
Multifunction steering wheel..................................................................................................................................................................................................................................................................................................................................................................................................................................12698
2. Steering column electronics control unit.......................................................................................................................................................................................................................................................................................................................................................................................................................12699
3. Operating unit in steering wheel, Multifunction buttons on left in steering wheel, Multifunction buttons on right in steering wheel, Multifunction steering wheel control unit, Steering column electronics control unit.......................................................................................................................................................................................................................................12700
4. Operating unit in steering wheel, Steering column electronics control unit, Driver side airbag igniter, Driver side airbag igniter 2...........................................................................................................................................................................................................................................................................................................................12701
034 -
Preparation for mobile telephone (infotainment CAN bus)........................................................................................................................................................................................................................................................................................................................................................................................................12702
1.
Preparation for mobile telephone (infotainment CAN bus).......................................................................................................................................................................................................................................................................................................................................................................................................12702
2. Radio, telephone and navigation system aerial, Remote control receiver for auxiliary heater, Telephone aerial, Aerial amplifier for mobile telephone, Auxiliary heater aerial..................................................................................................................................................................................................................................................................................12703
3. Telephone transmitter and receiver unit, Aerial amplifier for mobile telephone, Aerial for Bluetooth...........................................................................................................................................................................................................................................................................................................................................................12704
4. Radio, Telephone transmitter and receiver unit, Telephone microphone, Microphone unit in front roof module.....................................................................................................................................................................................................................................................................................................................................................12705
5. Telephone transmitter and receiver unit, Telephone bracket.....................................................................................................................................................................................................................................................................................................................................................................................................12706
035 -
Preparation for mobile telephone (MOST bus)....................................................................................................................................................................................................................................................................................................................................................................................................................12707
1.
Preparation for mobile telephone (MOST bus)...................................................................................................................................................................................................................................................................................................................................................................................................................12707
2. Radio, telephone and navigation system aerial, Remote control receiver for auxiliary heater, Aerial amplifier for mobile telephone, Auxiliary heater aerial....................................................................................................................................................................................................................................................................................................12708
3. Telephone transmitter and receiver unit, Aerial amplifier for mobile telephone.................................................................................................................................................................................................................................................................................................................................................................................12709
4. Data bus diagnostic interface, Telephone transmitter and receiver unit, Telephone microphone, Aerial for Bluetooth, Microphone unit in front roof module.......................................................................................................................................................................................................................................................................................................12710
5. Telephone transmitter and receiver unit, Telephone bracket.....................................................................................................................................................................................................................................................................................................................................................................................................12711
036 -
Bluetooth car phone (MOST bus).................................................................................................................................................................................................................................................................................................................................................................................................................................12712
1.
Bluetooth car phone (MOST bus)................................................................................................................................................................................................................................................................................................................................................................................................................................12712
2. Navigation system with CD drive control unit, Control unit for front display and information control panel, Telephone transmitter and receiver unit, Radio, telephone and navigation system aerial, Remote control receiver for auxiliary heater, Satellite
adio, Aerial for Bluetooth, Microphone unit in front roof module..................................................................................................................................12713
3. Onboard supply control unit, Telephone transmitter and receiver unit, Telephone bracket........................................................................................................................................................................................................................................................................................................................................................................12714
037 -
Preparation for mobile telephone with no hands-free system (infotainment CAN bus)..............................................................................................................................................................................................................................................................................................................................................................................12715
1.
Preparation for mobile telephone with no hands-free system (infotainment CAN bus).............................................................................................................................................................................................................................................................................................................................................................................12715
2. Radio, Radio, telephone and navigation system aerial, Microphone unit in front roof module.....................................................................................................................................................................................................................................................................................................................................................................12716
038 -
Preparation for mobile telephone with no hands-free system (MOST bus)..........................................................................................................................................................................................................................................................................................................................................................................................12717
1.
Preparation for mobile telephone with no hands-free system (MOST bus).........................................................................................................................................................................................................................................................................................................................................................................................12717
2. Microphone unit in front roof module...........................................................................................................................................................................................................................................................................................................................................................................................................................12718
3. Radio, telephone and navigation system aerial..................................................................................................................................................................................................................................................................................................................................................................................................................12719
039 -
Automatic air conditioning system, luxury Climatronic..........................................................................................................................................................................................................................................................................................................................................................................................................12720
1.
Automatic air conditioning system, luxury Climatronic.........................................................................................................................................................................................................................................................................................................................................................................................................12720
2. Fresh air blower control unit, Fresh air blower................................................................................................................................................................................................................................................................................................................................................................................................................12721
3. Sunlight penetration photosensor, Potentiometer for rear temperature selection.................................................................................................................................................................................................................................................................................................................................................................................12722
4. Defroster flap control motor, Right centre vent control motor..................................................................................................................................................................................................................................................................................................................................................................................................12723
5. Left footwell flap control motor, Left temperature flap control motor..........................................................................................................................................................................................................................................................................................................................................................................................12724
6. Left footwell vent temperature sender, Right footwell vent temperature sender, Evaporator output temperature sender, Air flow flap control motor, Air recirculation flap control motor.........................................................................................................................................................................................................................................................................12725
7. Coolant circulation pump.......................................................................................................................................................................................................................................................................................................................................................................................................................................12726
8. Ambient temperature sensor, Refrigerant pressure and temperature sender, Air conditioner compressor regulating valve...........................................................................................................................................................................................................................................................................................................................................12727
9. Convenience system central control unit, Frequency modulation (FM) frequency filter in negative wire, Frequency modulation (FM) frequency filter in positive wire, Heated rear window..........................................................................................................................................................................................................................................................................12728
10. Humidity sender, Convenience system central control unit, Automatic anti-dazzle interior mirror...............................................................................................................................................................................................................................................................................................................................................................12729
040 -
Automatic air conditioning system, basic Climatronic...........................................................................................................................................................................................................................................................................................................................................................................................................12730
1.
Automatic air conditioning system, basic Climatronic..........................................................................................................................................................................................................................................................................................................................................................................................................12730
2. Fresh air blower control unit..................................................................................................................................................................................................................................................................................................................................................................................................................................12731
3. Centre vent control motor......................................................................................................................................................................................................................................................................................................................................................................................................................................12732
4. Air recirculation flap control motor, Footwell flap control motor..............................................................................................................................................................................................................................................................................................................................................................................................12733
5. Centre vent temperature sender, Footwell vent temperature sender, Evaporator output temperature sender, Coolant circulation pump...............................................................................................................................................................................................................................................................................................................................12734
6. Air conditioner compressor regulating valve....................................................................................................................................................................................................................................................................................................................................................................................................................12735
7. Frequency modulation (FM) frequency filter in negative wire, Frequency modulation (FM) frequency filter in positive wire, Heated rear window...................................................................................................................................................................................................................................................................................................................12736
041 -
Ring circuit break diagnostic..................................................................................................................................................................................................................................................................................................................................................................................................................................12737
1.
Ring circuit break diagnostic.................................................................................................................................................................................................................................................................................................................................................................................................................................12737
2. Navigation system with CD drive control unit, Control unit for front display and information control panel, Digital sound package control unit, Radio, Telephone transmitter and receiver unit, TV tuner, Connection 1 (diagnosis), in main wiring harness.....................................................................................................................................................................................................12738
3. Control unit for front display and information control panel, Data bus diagnostic interface, CD changer, Satellite radio, Digital radio, Connection for external audio sources, Connection 1 (diagnosis), in main wiring harness...............................................................................................................................................................................................................................12739
042 -
Infotainment MOST bus..........................................................................................................................................................................................................................................................................................................................................................................................................................................12740
1.
Infotainment MOST bus.........................................................................................................................................................................................................................................................................................................................................................................................................................................12740
2. Control unit for front display and information control panel, Digital sound package control unit, Data bus diagnostic interface, Telephone transmitter and receiver unit, CD changer, Digital radio............................................................................................................................................................................................................................................................12741
3. Control unit for front display and information control panel, Data bus diagnostic interface, CD changer, Connection for external audio sources.................................................................................................................................................................................................................................................................................................................12742
4. Navigation system with CD drive control unit, Digital sound package control unit, Radio, Telephone transmitter and receiver unit, TV tuner, Satellite radio, Digital radio.....................................................................................................................................................................................................................................................................................12743
043 -
Anti-lock brake system (ABS) with electronic stabilisation program (ESP).......................................................................................................................................................................................................................................................................................................................................................................................12744
1.
Anti-lock brake system (ABS) with electronic stabilisation program (ESP)......................................................................................................................................................................................................................................................................................................................................................................................12744
2. Auto-hold button, ABS control unit, ABS control unit fuse 1....................................................................................................................................................................................................................................................................................................................................................................................................12745
3. TCS and ESP button, ABS control unit...........................................................................................................................................................................................................................................................................................................................................................................................................................12746
4. ESP sensor unit, ESP sensor unit 2, ABS control unit, Active steering control unit, ABS hydraulic pump.........................................................................................................................................................................................................................................................................................................................................................12747
5. Rear right speed sensor, Front right speed sensor, Rear left speed sensor, Front left speed sensor, ABS control unit...........................................................................................................................................................................................................................................................................................................................................12748
6. Brake light switch, ABS control unit, Convenience system central control unit, ABS hydraulic unit, Front right ABS inlet valve, Front right ABS outlet valve, Front left ABS inlet valve, Front left ABS outlet valve, Rear right ABS inlet valve, Rear left ABS inlet valve, Rear right ABS outlet valve, Rear left ABS outlet valve..........................................................................................................................12749
7. Steering angle sender, ABS control unit, Steering column electronics control unit, ABS hydraulic unit, Vehicle stabilization program switch valve 1, Vehicle stabilization program switch valve 2, Vehicle stabilization program high-pressure valve 1, Vehicle stabilization program high-pressure valve 2....................................................................................................................................................12750
8. Control unit in dash panel insert, Data bus diagnostic interface, ABS warning lamp, ESP and TCS warning lamp...................................................................................................................................................................................................................................................................................................................................................12751
044 -
MMI basic......................................................................................................................................................................................................................................................................................................................................................................................................................................................12752
1.
MMI basic.....................................................................................................................................................................................................................................................................................................................................................................................................................................................12752
2. Control unit for front display and information control panel...................................................................................................................................................................................................................................................................................................................................................................................................12753
3. Multimedia system operating unit, Control unit for front display and information control panel, Display unit for front information display and operating unit control unit.....................................................................................................................................................................................................................................................................................12754
4. Control unit for front display and information control panel, Radio, telephone and navigation system aerial, Aerial amplifier 2, Aerial amplifier 3............................................................................................................................................................................................................................................................................................................12755
045 -
CD/DVD changer (MOST bus)......................................................................................................................................................................................................................................................................................................................................................................................................................................12756
1.
CD/DVD changer (MOST bus).....................................................................................................................................................................................................................................................................................................................................................................................................................................12756
2. CD changer, Connection for external audio sources..............................................................................................................................................................................................................................................................................................................................................................................................................12757
046 -
MMI with digital radio.........................................................................................................................................................................................................................................................................................................................................................................................................................................12758
1.
MMI with digital radio........................................................................................................................................................................................................................................................................................................................................................................................................................................12758
2. TV tuner, Aerial amplifier 2, Aerial amplifier 3, Digital radio................................................................................................................................................................................................................................................................................................................................................................................................12759
047 -
MMI with radio and basic sound system..........................................................................................................................................................................................................................................................................................................................................................................................................................12760
1.
MMI with radio and basic sound system.........................................................................................................................................................................................................................................................................................................................................................................................................................12760
2. Digital sound package control unit.............................................................................................................................................................................................................................................................................................................................................................................................................................12761
3. Digital sound package control unit, Front left treble loudspeaker, Front right treble loudspeaker, Front left mid-range and bass loudspeaker, Front right mid-range and bass loudspeaker.......................................................................................................................................................................................................................................................................12762
4. Digital sound package control unit, Rear left treble loudspeaker, Rear right treble loudspeaker, Rear left mid-range and bass loudspeaker, Rear right mid-range and bass loudspeaker...........................................................................................................................................................................................................................................................................12763
048 -
MMI with radio and Standard sound system.......................................................................................................................................................................................................................................................................................................................................................................................................................12764
1.
MMI with radio and Standard sound system......................................................................................................................................................................................................................................................................................................................................................................................................................12764
2. Digital sound package control unit, Telephone microphone, Microphone unit in front roof module, Voice command microphone.......................................................................................................................................................................................................................................................................................................................................12765
3. Digital sound package control unit, Front left treble loudspeaker, Front right treble loudspeaker, Front left mid-range and bass loudspeaker, Front right mid-range and bass loudspeaker, Centre mid-range and treble loudspeaker..............................................................................................................................................................................................................................12766
4. Digital sound package control unit, Rear left treble loudspeaker, Rear right treble loudspeaker, Subwoofer in rear shelf, Rear left mid-range and bass loudspeaker, Rear right mid-range and bass loudspeaker..................................................................................................................................................................................................................................................12767
5. Digital sound package control unit, Connection for external audio sources......................................................................................................................................................................................................................................................................................................................................................................................12768
049 -
MMI with radio and Bang & Olufsen sound system.................................................................................................................................................................................................................................................................................................................................................................................................................12769
1.
MMI with radio and Bang & Olufsen sound system................................................................................................................................................................................................................................................................................................................................................................................................................12769
2. Digital sound package control unit, Telephone microphone, Internal microphone, Microphone unit in front roof module, Voice command microphone..................................................................................................................................................................................................................................................................................................................12770
3. Digital sound package control unit, Front left treble loudspeaker, Front left bass loudspeaker, Front left mid-range loudspeaker, Centre mid-range and treble loudspeaker......................................................................................................................................................................................................................................................................................12771
4. Digital sound package control unit, Front right treble loudspeaker, Front right bass loudspeaker, Front right mid-range loudspeaker............................................................................................................................................................................................................................................................................................................................12772
5. Digital sound package control unit, Rear left treble loudspeaker, Rear right treble loudspeaker, Rear left mid-range and bass loudspeaker, Rear right mid-range and bass loudspeaker...........................................................................................................................................................................................................................................................................12773
6. Digital sound package control unit, Rear left mid-range loudspeaker, Rear right mid-range loudspeaker, Subwoofer in rear shelf.................................................................................................................................................................................................................................................................................................................................12774
7. Digital sound package control unit, Connection for external audio sources......................................................................................................................................................................................................................................................................................................................................................................................12775
050 -
Preparation for mobile telephone (infotainment CAN bus) - USA..................................................................................................................................................................................................................................................................................................................................................................................................12776
1.
Preparation for mobile telephone (infotainment CAN bus) - USA.................................................................................................................................................................................................................................................................................................................................................................................................12776
2. Telephone transmitter and receiver unit, Aerial for Bluetooth..................................................................................................................................................................................................................................................................................................................................................................................................12777
3. Radio, Telephone transmitter and receiver unit, Front left microphone, Microphone unit in front roof module....................................................................................................................................................................................................................................................................................................................................................12778
4. Telephone transmitter and receiver unit, Telephone bracket.....................................................................................................................................................................................................................................................................................................................................................................................................12779
5. Radio, telephone and navigation system aerial, Telephone aerial, Telephone bracket, Satellite aerial...........................................................................................................................................................................................................................................................................................................................................................12780
051 -
MMI high with navigation system................................................................................................................................................................................................................................................................................................................................................................................................................................12781
1.
MMI high with navigation system...............................................................................................................................................................................................................................................................................................................................................................................................................................12781
2. Navigation system with CD drive control unit, Radio, telephone and navigation system aerial, Satellite aerial, Auxiliary heater aerial.........................................................................................................................................................................................................................................................................................................................12782
052 -
MMI High.......................................................................................................................................................................................................................................................................................................................................................................................................................................................12783
1.
MMI High......................................................................................................................................................................................................................................................................................................................................................................................................................................................12783
2. Multimedia system operating unit, Control unit for front display and information control panel.................................................................................................................................................................................................................................................................................................................................................................12784
3. Control unit for front display and information control panel, Display unit for front information display and operating unit control unit.......................................................................................................................................................................................................................................................................................................................12785
4. Control unit for front display and information control panel, Display unit for front information display and operating unit control unit, Reversing camera system control unit, TV tuner.......................................................................................................................................................................................................................................................................12786
053 -
MMI high with radio............................................................................................................................................................................................................................................................................................................................................................................................................................................12787
1.
MMI high with radio...........................................................................................................................................................................................................................................................................................................................................................................................................................................12787
2. Radio, Aerial amplifier 2, Aerial amplifier 3..................................................................................................................................................................................................................................................................................................................................................................................................................12788
054 -
MMI high with TV tuner.........................................................................................................................................................................................................................................................................................................................................................................................................................................12789
1.
MMI high with TV tuner........................................................................................................................................................................................................................................................................................................................................................................................................................................12789
2. Control unit for front display and information control panel, Reversing camera system control unit, TV tuner...................................................................................................................................................................................................................................................................................................................................................12790
3. TV tuner, Aerial amplifier 2, Aerial amplifier 3...............................................................................................................................................................................................................................................................................................................................................................................................................12791
055 -
MMI with satellite radio.......................................................................................................................................................................................................................................................................................................................................................................................................................................12792
1.
MMI with satellite radio......................................................................................................................................................................................................................................................................................................................................................................................................................................12792
2. Navigation system with CD drive control unit, Radio, telephone and navigation system aerial, Telephone bracket, Satellite radio, Satellite aerial..............................................................................................................................................................................................................................................................................................................12793
056 -
Radio with basic and basic plus sound system...................................................................................................................................................................................................................................................................................................................................................................................................................12794
1.
Radio with basic and basic plus sound system..................................................................................................................................................................................................................................................................................................................................................................................................................12794
2. Radio, Telephone transmitter and receiver unit.................................................................................................................................................................................................................................................................................................................................................................................................................12795
3. Data bus diagnostic interface, Display unit for front information display and operating unit control unit, Radio...............................................................................................................................................................................................................................................................................................................................................12796
4. Radio, Front left treble loudspeaker, Front right treble loudspeaker, Front left mid-range and bass loudspeaker, Front right mid-range and bass loudspeaker....................................................................................................................................................................................................................................................................................................12797
5. Radio, Front left treble loudspeaker, Front right treble loudspeaker, Front left mid-range and bass loudspeaker, Front right mid-range and bass loudspeaker....................................................................................................................................................................................................................................................................................................12798
6. Radio, Rear left treble loudspeaker, Rear right treble loudspeaker, Rear left mid-range and bass loudspeaker, Rear right mid-range and bass loudspeaker........................................................................................................................................................................................................................................................................................................12799
7. Radio, Radio, telephone and navigation system aerial, Aerial amplifier 2, Aerial amplifier 3, Satellite aerial.................................................................................................................................................................................................................................................................................................................................................12800
8. Radio, Connection for external audio sources...................................................................................................................................................................................................................................................................................................................................................................................................................12801
9. Radio..........................................................................................................................................................................................................................................................................................................................................................................................................................................................12802
057 -
Radio with Standard sound system...............................................................................................................................................................................................................................................................................................................................................................................................................................12803
1.
Radio with Standard sound system..............................................................................................................................................................................................................................................................................................................................................................................................................................12803
2. Radio, Telephone transmitter and receiver unit.................................................................................................................................................................................................................................................................................................................................................................................................................12804
3. Display unit for front information display and operating unit control unit, Radio..............................................................................................................................................................................................................................................................................................................................................................................12805
4. Digital sound package control unit, Data bus diagnostic interface, Radio.......................................................................................................................................................................................................................................................................................................................................................................................12806
5. Digital sound package control unit, Radio, Front left treble loudspeaker, Front left mid-range and bass loudspeaker............................................................................................................................................................................................................................................................................................................................................12807
6. Digital sound package control unit, Radio, Front right treble loudspeaker, Front right mid-range and bass loudspeaker, Centre mid-range and treble loudspeaker.................................................................................................................................................................................................................................................................................................12808
7. Digital sound package control unit, Radio, Rear left treble loudspeaker, Rear right treble loudspeaker, Subwoofer in rear shelf, Rear left mid-range and bass loudspeaker, Rear right mid-range and bass loudspeaker...........................................................................................................................................................................................................................................12809
8. Radio, Radio, telephone and navigation system aerial, Aerial amplifier 2, Aerial amplifier 3, Satellite aerial.................................................................................................................................................................................................................................................................................................................................................12810
9. Radio, Connection for external audio sources...................................................................................................................................................................................................................................................................................................................................................................................................................12811
10. Radio.........................................................................................................................................................................................................................................................................................................................................................................................................................................................12812
058 -
Radio with Bang & Olufsen sound system.........................................................................................................................................................................................................................................................................................................................................................................................................................12813
1.
Radio with Bang & Olufsen sound system........................................................................................................................................................................................................................................................................................................................................................................................................................12813
2. Radio, Telephone transmitter and receiver unit.................................................................................................................................................................................................................................................................................................................................................................................................................12814
3. Display unit for front information display and operating unit control unit, Radio..............................................................................................................................................................................................................................................................................................................................................................................12815
4. Digital sound package control unit, Data bus diagnostic interface, Radio.......................................................................................................................................................................................................................................................................................................................................................................................12816
5. Digital sound package control unit, Radio, Microphone unit in front roof module................................................................................................................................................................................................................................................................................................................................................................................12817
6. Digital sound package control unit, Radio, Front left treble loudspeaker, Front left bass loudspeaker, Front left mid-range loudspeaker, Centre mid-range and treble loudspeaker...............................................................................................................................................................................................................................................................................12818
7. Digital sound package control unit, Radio, Front right treble loudspeaker, Front right bass loudspeaker, Front right mid-range loudspeaker.....................................................................................................................................................................................................................................................................................................................12819
8. Digital sound package control unit, Radio, Rear left treble loudspeaker, Rear right treble loudspeaker, Rear left mid-range and bass loudspeaker, Rear right mid-range and bass loudspeaker....................................................................................................................................................................................................................................................................12820
9. Digital sound package control unit, Radio, Rear left mid-range loudspeaker, Subwoofer in rear shelf............................................................................................................................................................................................................................................................................................................................................................12821
10. Radio, Radio, telephone and navigation system aerial, Aerial amplifier 2, Aerial amplifier 3, Satellite aerial................................................................................................................................................................................................................................................................................................................................................12822
11. Radio, Connection for external audio sources..................................................................................................................................................................................................................................................................................................................................................................................................................12823
12. Radio.........................................................................................................................................................................................................................................................................................................................................................................................................................................................12824
059 -
Interior mirror with no humidity sender and no main beam assist................................................................................................................................................................................................................................................................................................................................................................................................12825
1.
Interior mirror with no humidity sender and no main beam assist...............................................................................................................................................................................................................................................................................................................................................................................................12825
2. Automatic anti-dazzle interior mirror..........................................................................................................................................................................................................................................................................................................................................................................................................................12826
3. Driver door control unit, Front passenger door control unit, Automatic anti-dazzle interior mirror.............................................................................................................................................................................................................................................................................................................................................................12827
060 -
Interior mirror with humidity sender and no main beam assist...................................................................................................................................................................................................................................................................................................................................................................................................12828
1.
Interior mirror with humidity sender and no main beam assist..................................................................................................................................................................................................................................................................................................................................................................................................12828
2. Humidity sender, Automatic anti-dazzle interior mirror.........................................................................................................................................................................................................................................................................................................................................................................................................12829
3. Driver door control unit, Front passenger door control unit, Automatic anti-dazzle interior mirror.............................................................................................................................................................................................................................................................................................................................................................12830
061 -
Interior mirror with humidity sender and main beam assist......................................................................................................................................................................................................................................................................................................................................................................................................12831
1.
Interior mirror with humidity sender and main beam assist.....................................................................................................................................................................................................................................................................................................................................................................................................12831
2. Humidity sender, Automatic anti-dazzle interior mirror.........................................................................................................................................................................................................................................................................................................................................................................................................12832
3. Driver door control unit, Front passenger door control unit, Automatic anti-dazzle interior mirror.............................................................................................................................................................................................................................................................................................................................................................12833
062 -
Tyre pressure monitor..........................................................................................................................................................................................................................................................................................................................................................................................................................................12834
1.
Tyre pressure monitor.........................................................................................................................................................................................................................................................................................................................................................................................................................................12834
2. Tyre pressure monitor control unit.............................................................................................................................................................................................................................................................................................................................................................................................................................12835
063 -
2.0l diesel engine , CAGA,CAGB,CAHA,CAHB,CMEA..................................................................................................................................................................................................................................................................................................................................................................................................................12836
1.
2.0l diesel engine , CAGA,CAGB,CAHA,CAHB,CMEA.................................................................................................................................................................................................................................................................................................................................................................................................................12836
2. Battery, Terminal 15 voltage supply relay......................................................................................................................................................................................................................................................................................................................................................................................................................12837
3. Battery isolation igniter, Jump start socket...................................................................................................................................................................................................................................................................................................................................................................................................................12838
4. Starter, Alternator, Voltage regulator, Terminal 30 wiring junction 2, Jump start socket.......................................................................................................................................................................................................................................................................................................................................................................12839
5. Fuel pump relay, Terminal 30 voltage supply relay, Engine control unit.........................................................................................................................................................................................................................................................................................................................................................................................12840
6. Starter motor relay, Engine control unit, Starter motor relay 2................................................................................................................................................................................................................................................................................................................................................................................................12841
7. Automatic glow period control unit, Engine control unit........................................................................................................................................................................................................................................................................................................................................................................................................12842
8. Oil level and oil temperature sender, Engine control unit, Climatronic coolant shut-off valve, Pump for exhaust gas recirculation cooler.......................................................................................................................................................................................................................................................................................................................12843
9. Engine control unit, Charge pressure control solenoid valve, Heater element for crankcase breather, Left electrohydraulic engine mounting solenoid valve, Air filter bypass flap valve, Exhaust gas recirculation cooler changeover valve......................................................................................................................................................................................................................12844
10. Low heat output relay, High heat output relay, Engine control unit, Auxiliary air heater element..............................................................................................................................................................................................................................................................................................................................................................12845
11. Accelerator position sender, Accelerator position sender 2, Engine control unit...............................................................................................................................................................................................................................................................................................................................................................................12846
12. Engine speed sender, Hall sender, Variable intake manifold position sender, Engine control unit, Variable intake manifold motor...............................................................................................................................................................................................................................................................................................................................12847
13. Throttle valve potentiometer, Exhaust gas recirculation potentiometer, Fuel pressure sender, Engine control unit, Exhaust gas recirculation valve, Intake manifold flap motor.................................................................................................................................................................................................................................................................................12848
14. Charge pressure sender, Intake air temperature sender, Fuel temperature sender, Exhaust gas pressure sensor 1, Position sender for charge pressure positioner, Engine control unit............................................................................................................................................................................................................................................................................12849
15. Air mass meter, Engine control unit, Fuel pressure regulating valve, Fuel metering valve......................................................................................................................................................................................................................................................................................................................................................................12850
16. Coolant temperature sender, Radiator outlet coolant temperature sender, Exhaust gas temperature sender 1, Exhaust gas temperature sender 3, Exhaust gas temperature sender 4, Engine control unit.............................................................................................................................................................................................................................................................12851
17. Lambda probe, Engine control unit.............................................................................................................................................................................................................................................................................................................................................................................................................................12852
18. Engine control unit, Injector, cylinder 1, Injector, cylinder 2, Injector, cylinder 3, Injector, cylinder 4...................................................................................................................................................................................................................................................................................................................................................12853
19. Clutch position sender, Engine control unit...................................................................................................................................................................................................................................................................................................................................................................................................................12854
20. Brake light switch, Engine control unit, Supplementary fuel pump..............................................................................................................................................................................................................................................................................................................................................................................................12855
21. Data bus diagnostic interface, Engine control unit............................................................................................................................................................................................................................................................................................................................................................................................................12856
22. Control unit in dash panel insert, Data bus diagnostic interface..............................................................................................................................................................................................................................................................................................................................................................................................12857
23. Fuel gauge sender, Fuel system pressurisation pump, Control unit in dash panel insert.........................................................................................................................................................................................................................................................................................................................................................................12858
24. Oil pressure switch, Gear detector switch, Coolant shortage indicator sender, Onboard supply control unit, Servotronic solenoid valve, Air conditioner compressor regulating valve............................................................................................................................................................................................................................................................................12859
064 -
2.0l petrol engine , CAEA,CAEB,CDNB,CDNC.......................................................................................................................................................................................................................................................................................................................................................................................................................12860
1.
2.0l petrol engine , CAEA,CAEB,CDNB,CDNC......................................................................................................................................................................................................................................................................................................................................................................................................................12860
2. Battery, Terminal 15 voltage supply relay......................................................................................................................................................................................................................................................................................................................................................................................................................12861
3. Battery isolation igniter, Jump start socket...................................................................................................................................................................................................................................................................................................................................................................................................................12862
4. Starter, Alternator, Voltage regulator, Terminal 30 wiring junction 2, Jump start socket.......................................................................................................................................................................................................................................................................................................................................................................12863
5. Main relay, Engine component current supply relay..............................................................................................................................................................................................................................................................................................................................................................................................................12864
6. Starter motor relay, Starter motor relay 2.....................................................................................................................................................................................................................................................................................................................................................................................................................12865
7. Charge pressure control solenoid valve, Activated charcoal filter solenoid valve 1, Left electrohydraulic engine mounting solenoid valve, Camshaft control valve 1, Turbocharger air recirculation valve, Valve for oil pressure control.......................................................................................................................................................................................................................12866
8. Climatronic coolant shut-off valve, Continued coolant circulation pump.........................................................................................................................................................................................................................................................................................................................................................................................12867
9. Actuator 1 for camshaft adjustment, Actuator 6 for camshaft adjustment, Actuator 7 for camshaft adjustment.....................................................................................................................................................................................................................................................................................................................................................12868
10. Actuator 8 for camshaft adjustment, Ignition coil 1 with output stage, Ignition coil 2 with output stage, Ignition coil 3 with output stage, Ignition coil 4 with output stage................................................................................................................................................................................................................................................................................12869
11. Accelerator position sender, Accelerator position sender 2....................................................................................................................................................................................................................................................................................................................................................................................................12870
12. Engine speed sender, Hall sender..............................................................................................................................................................................................................................................................................................................................................................................................................................12871
13. Fuel pressure sender, Intake manifold flap potentiometer......................................................................................................................................................................................................................................................................................................................................................................................................12872
14. Oil pressure switch for reduced oil pressure, Throttle valve module...........................................................................................................................................................................................................................................................................................................................................................................................12873
15. Injector, cylinder 1, Injector, cylinder 2, Injector, cylinder 3, Injector, cylinder 4, Fuel pressure regulating valve........................................................................................................................................................................................................................................................................................................................................12874
16. Lambda probe, Lambda probe after catalytic converter..........................................................................................................................................................................................................................................................................................................................................................................................................12875
17. Clutch position sender........................................................................................................................................................................................................................................................................................................................................................................................................................................12876
18. Brake light switch, Steering column electronics control unit..................................................................................................................................................................................................................................................................................................................................................................................................12877
19. Data bus diagnostic interface.................................................................................................................................................................................................................................................................................................................................................................................................................................12878
20. Control unit in dash panel insert, Data bus diagnostic interface..............................................................................................................................................................................................................................................................................................................................................................................................12879
21. Fuel gauge sender, Fuel system pressurisation pump, Fuel gauge sender 2, Control unit in dash panel insert, Fuel pump control unit............................................................................................................................................................................................................................................................................................................................12880
22. Oil pressure switch, Coolant shortage indicator sender, Onboard supply control unit...........................................................................................................................................................................................................................................................................................................................................................................12881
065 -
Lane departure warning.........................................................................................................................................................................................................................................................................................................................................................................................................................................12882
1.
Lane departure warning........................................................................................................................................................................................................................................................................................................................................................................................................................................12882
2. Data bus diagnostic interface, Lane departure warning control unit.............................................................................................................................................................................................................................................................................................................................................................................................12883
3. Lane departure warning control unit, Windscreen heater for lane departure warning..............................................................................................................................................................................................................................................................................................................................................................................12884
066 -
Lane change assist.............................................................................................................................................................................................................................................................................................................................................................................................................................................12885
1.
Lane change assist............................................................................................................................................................................................................................................................................................................................................................................................................................................12885
2. Lane change assist control unit................................................................................................................................................................................................................................................................................................................................................................................................................................12886
3. Lane change assist control unit 2..............................................................................................................................................................................................................................................................................................................................................................................................................................12887
4. Button for lane change assist, Lane change assist warning lamp in driver side exterior mirror, Lane change assist warning lamp in front passenger side exterior mirror.........................................................................................................................................................................................................................................................................................12888
067 -
Interface for special functions................................................................................................................................................................................................................................................................................................................................................................................................................................12889
1.
Interface for special functions...............................................................................................................................................................................................................................................................................................................................................................................................................................12889
2. Convenience system central control unit, Interface control unit for vehicle location system....................................................................................................................................................................................................................................................................................................................................................................12890
3. Brake light switch, Accelerator position sender, Engine control unit...........................................................................................................................................................................................................................................................................................................................................................................................12891
068 -
Active steering (dynamic steering).............................................................................................................................................................................................................................................................................................................................................................................................................................12892
1.
Active steering (dynamic steering)............................................................................................................................................................................................................................................................................................................................................................................................................................12892
2. Active steering control unit, Electromechanical power steering motor...........................................................................................................................................................................................................................................................................................................................................................................................12893
3. Lateral acceleration sender, Yaw rate sender, Longitudinal acceleration sender, ESP sensor unit, ESP sensor unit 2, ABS control unit, Active steering control unit.............................................................................................................................................................................................................................................................................................12894
4. Control unit in dash panel insert, Active steering control unit, Steering hydraulics pump......................................................................................................................................................................................................................................................................................................................................................................12895
069 -
Communication, Japan...........................................................................................................................................................................................................................................................................................................................................................................................................................................12896
1.
Communication, Japan..........................................................................................................................................................................................................................................................................................................................................................................................................................................12896
2. Control unit for front display and information control panel...................................................................................................................................................................................................................................................................................................................................................................................................12897
3. Control unit for front display and information control panel, Display unit for front information display and operating unit control unit.......................................................................................................................................................................................................................................................................................................................12898
4. Navigation system with CD drive control unit, Control unit for front display and information control panel, Display unit for front information display and operating unit control unit.........................................................................................................................................................................................................................................................................12899
5. Navigation system with CD drive control unit...................................................................................................................................................................................................................................................................................................................................................................................................................12900
6. Navigation system with CD drive control unit, Microphone unit in front roof module.............................................................................................................................................................................................................................................................................................................................................................................12901
7. Navigation system with CD drive control unit...................................................................................................................................................................................................................................................................................................................................................................................................................12902
8. Navigation system with CD drive control unit, Chip card reader control unit....................................................................................................................................................................................................................................................................................................................................................................................12903
9. Navigation system with CD drive control unit, Chip card reader control unit....................................................................................................................................................................................................................................................................................................................................................................................12904
10. Navigation system with CD drive control unit, Chip card reader control unit...................................................................................................................................................................................................................................................................................................................................................................................12905
11. Radio, Aerial amplifier 3.....................................................................................................................................................................................................................................................................................................................................................................................................................................12906
12. Reversing camera system control unit, TV tuner................................................................................................................................................................................................................................................................................................................................................................................................................12907
13. TV tuner, TV card reader......................................................................................................................................................................................................................................................................................................................................................................................................................................12908
14. CD changer, Connection for external audio sources.............................................................................................................................................................................................................................................................................................................................................................................................................12909
070 -
6-cylinder diesel engine , CCWA,CCWB,CGKA,CGKB.................................................................................................................................................................................................................................................................................................................................................................................................................12910
1.
6-cylinder diesel engine , CCWA,CCWB,CGKA,CGKB................................................................................................................................................................................................................................................................................................................................................................................................................12910
2. Battery, Terminal 15 voltage supply relay......................................................................................................................................................................................................................................................................................................................................................................................................................12911
3. Battery isolation igniter, Jump start socket...................................................................................................................................................................................................................................................................................................................................................................................................................12912
4. Starter, Alternator, Voltage regulator, Terminal 30 wiring junction 2, Jump start socket.......................................................................................................................................................................................................................................................................................................................................................................12913
5. Fuel pump relay, Terminal 30 voltage supply relay, Engine control unit.........................................................................................................................................................................................................................................................................................................................................................................................12914
6. Starter motor relay, Engine control unit, Starter motor relay 2................................................................................................................................................................................................................................................................................................................................................................................................12915
7. Automatic glow period control unit, Engine control unit........................................................................................................................................................................................................................................................................................................................................................................................................12916
8. Oil level and oil temperature sender, Engine control unit......................................................................................................................................................................................................................................................................................................................................................................................................12917
9. Throttle valve module, Engine control unit, Left electrohydraulic engine mounting solenoid valve, Right electrohydraulic engine mounting solenoid valve........................................................................................................................................................................................................................................................................................................12918
10. Low heat output relay, Engine control unit, Auxiliary air heater element......................................................................................................................................................................................................................................................................................................................................................................................12919
11. Engine speed sender, Hall sender, Fuel pressure sender, Engine control unit...................................................................................................................................................................................................................................................................................................................................................................................12920
12. Accelerator position sender, Accelerator position sender 2, Engine control unit...............................................................................................................................................................................................................................................................................................................................................................................12921
13. Exhaust gas pressure sensor 1, Engine control unit, Intake manifold flap motor, Intake manifold flap 2 motor..................................................................................................................................................................................................................................................................................................................................................12922
14. Engine control unit, Turbocharger 1 control unit, Exhaust gas recirculation control motor.....................................................................................................................................................................................................................................................................................................................................................................12923
15. Charge pressure sender, Intake air temperature sender, Engine control unit....................................................................................................................................................................................................................................................................................................................................................................................12924
16. Air mass meter, Engine control unit...........................................................................................................................................................................................................................................................................................................................................................................................................................12925
17. Oil pressure switch for reduced oil pressure, Coolant temperature sender, Engine control unit.................................................................................................................................................................................................................................................................................................................................................................12926
18. Lambda probe, Engine control unit.............................................................................................................................................................................................................................................................................................................................................................................................................................12927
19. Engine control unit, Injector, cylinder 1, Injector, cylinder 6...............................................................................................................................................................................................................................................................................................................................................................................................12928
20. Clutch position sender, Engine control unit...................................................................................................................................................................................................................................................................................................................................................................................................................12929
21. Brake light switch, Engine control unit, Supplementary fuel pump..............................................................................................................................................................................................................................................................................................................................................................................................12930
22. Engine control unit...........................................................................................................................................................................................................................................................................................................................................................................................................................................12931
23. Control unit in dash panel insert, Data bus diagnostic interface..............................................................................................................................................................................................................................................................................................................................................................................................12932
24. Fuel gauge sender, Fuel system pressurisation pump, Fuel gauge sender 2, Control unit in dash panel insert....................................................................................................................................................................................................................................................................................................................................................12933
25. Gear detector switch, Onboard supply control unit, Air conditioner compressor regulating valve................................................................................................................................................................................................................................................................................................................................................................12934
071 -
Preparation for mobile telephone (infotainment CAN bus)........................................................................................................................................................................................................................................................................................................................................................................................................12935
1.
Preparation for mobile telephone (infotainment CAN bus).......................................................................................................................................................................................................................................................................................................................................................................................................12935
2. Radio, telephone and navigation system aerial, Remote control receiver for auxiliary heater, Telephone aerial, Aerial amplifier for mobile telephone, Auxiliary heater aerial..................................................................................................................................................................................................................................................................................12936
3. Telephone transmitter and receiver unit, Aerial amplifier for mobile telephone, Aerial for Bluetooth...........................................................................................................................................................................................................................................................................................................................................................12937
4. Radio, Telephone transmitter and receiver unit, Front left microphone, Microphone unit in front roof module....................................................................................................................................................................................................................................................................................................................................................12938
5. Telephone transmitter and receiver unit, Telephone bracket.....................................................................................................................................................................................................................................................................................................................................................................................................12939
072 -
Adaptive cruise control........................................................................................................................................................................................................................................................................................................................................................................................................................................12940
1.
Adaptive cruise control.......................................................................................................................................................................................................................................................................................................................................................................................................................................12940
2. Adaptive cruise control unit...................................................................................................................................................................................................................................................................................................................................................................................................................................12941
073 -
Preparation for mobile telephone (MOST bus)....................................................................................................................................................................................................................................................................................................................................................................................................................12942
1.
Preparation for mobile telephone (MOST bus)...................................................................................................................................................................................................................................................................................................................................................................................................................12942
2. Radio, telephone and navigation system aerial, Remote control receiver for auxiliary heater, Aerial amplifier for mobile telephone, Auxiliary heater aerial....................................................................................................................................................................................................................................................................................................12943
3. Control unit for front display and information control panel, Aerial amplifier for mobile telephone, Telephone bracket.........................................................................................................................................................................................................................................................................................................................................12944
4. Control unit for front display and information control panel, Data bus diagnostic interface, Telephone microphone, Aerial for Bluetooth, Microphone unit in front roof module, Voice command microphone........................................................................................................................................................................................................................................................12945
074 -
MMI with radio and basic sound system..........................................................................................................................................................................................................................................................................................................................................................................................................................12946
1.
MMI with radio and basic sound system.........................................................................................................................................................................................................................................................................................................................................................................................................................12946
2. Radio..........................................................................................................................................................................................................................................................................................................................................................................................................................................................12947
3. Radio, Front left treble loudspeaker, Front right treble loudspeaker, Front left mid-range and bass loudspeaker, Front right mid-range and bass loudspeaker....................................................................................................................................................................................................................................................................................................12948
4. Radio, Rear left treble loudspeaker, Rear right treble loudspeaker, Rear left mid-range and bass loudspeaker, Rear right mid-range and bass loudspeaker........................................................................................................................................................................................................................................................................................................12949
5. Convenience system central control unit, Radio, Central locking and anti-theft alarm system aerial, TV tuner, Aerial amplifier 3...............................................................................................................................................................................................................................................................................................................................12950
6. Control unit 1 for information electronics, Radio, GPS aerial, Radio, telephone and navigation system aerial, Remote control receiver for auxiliary heater, Telephone aerial, TV tuner, Aerial amplifier 2, Satellite aerial, Auxiliary heater aerial, Digital radio aerial....................................................................................................................................................................................12951
075 -
MMI with radio and Standard sound system.......................................................................................................................................................................................................................................................................................................................................................................................................................12952
1.
MMI with radio and Standard sound system......................................................................................................................................................................................................................................................................................................................................................................................................................12952
2. Radio..........................................................................................................................................................................................................................................................................................................................................................................................................................................................12953
3. Radio, Front left treble loudspeaker, Front left mid-range and bass loudspeaker, Centre mid-range and treble loudspeaker.......................................................................................................................................................................................................................................................................................................................................12954
4. Radio, Front right treble loudspeaker, Front right mid-range and bass loudspeaker..............................................................................................................................................................................................................................................................................................................................................................................12955
5. Radio, Rear left treble loudspeaker, Rear right treble loudspeaker, Subwoofer in rear shelf, Rear left mid-range and bass loudspeaker, Rear right mid-range and bass loudspeaker...............................................................................................................................................................................................................................................................................12956
6. Radio, Central locking and anti-theft alarm system aerial, Aerial amplifier 3..................................................................................................................................................................................................................................................................................................................................................................................12957
7. Radio, GPS aerial, Radio, telephone and navigation system aerial, Telephone aerial, Aerial amplifier 2, Satellite aerial, Auxiliary heater aerial, Digital radio aerial........................................................................................................................................................................................................................................................................................12958
076 -
MMI with radio and Bang & Olufsen sound system.................................................................................................................................................................................................................................................................................................................................................................................................................12959
1.
MMI with radio and Bang & Olufsen sound system................................................................................................................................................................................................................................................................................................................................................................................................................12959
2. Radio..........................................................................................................................................................................................................................................................................................................................................................................................................................................................12960
3. Convenience system central control unit, Radio, Central locking and anti-theft alarm system aerial, TV tuner, Aerial amplifier 3...............................................................................................................................................................................................................................................................................................................................12961
4. Control unit 1 for information electronics, Radio, GPS aerial, Radio, telephone and navigation system aerial, Remote control receiver for auxiliary heater, Telephone aerial, TV tuner, Aerial amplifier 2, Satellite aerial, Auxiliary heater aerial..........................................................................................................................................................................................................12962
5. Digital sound package control unit, Internal microphone, Front left microphone, Front right microphone, Microphone unit in front roof module...................................................................................................................................................................................................................................................................................................................12963
6. Digital sound package control unit, Front left treble loudspeaker, Front left bass loudspeaker, Front left mid-range loudspeaker...............................................................................................................................................................................................................................................................................................................................12964
7. Digital sound package control unit, Front right treble loudspeaker, Front right bass loudspeaker, Front right mid-range loudspeaker, Centre mid-range and treble loudspeaker...................................................................................................................................................................................................................................................................................12965
8. Digital sound package control unit, Rear left treble loudspeaker, Rear right treble loudspeaker, Rear left mid-range and bass loudspeaker, Rear right mid-range and bass loudspeaker...........................................................................................................................................................................................................................................................................12966
9. Digital sound package control unit, Rear left mid-range loudspeaker, Rear right mid-range loudspeaker, Subwoofer in rear shelf.................................................................................................................................................................................................................................................................................................................................12967
077 -
MMI (information electronics 1)................................................................................................................................................................................................................................................................................................................................................................................................................................12968
1.
MMI (information electronics 1)...............................................................................................................................................................................................................................................................................................................................................................................................................................12968
2. Control unit 1 for information electronics.....................................................................................................................................................................................................................................................................................................................................................................................................................12969
3. Display unit for front information display and operating unit control unit, Control unit 1 for information electronics.........................................................................................................................................................................................................................................................................................................................................12970
4. Multimedia system operating unit, Reversing camera system control unit, Control unit 1 for information electronics, TV tuner...................................................................................................................................................................................................................................................................................................................................12971
5. Control unit 1 for information electronics, Connection for external audio sources..............................................................................................................................................................................................................................................................................................................................................................................12972
6. Control unit 1 for information electronics, Connection for external audio sources..............................................................................................................................................................................................................................................................................................................................................................................12973
7. Control unit 1 for information electronics, Central locking and anti-theft alarm system aerial, Aerial amplifier 3.............................................................................................................................................................................................................................................................................................................................................12974
8. Control unit 1 for information electronics, GPS aerial, Radio, telephone and navigation system aerial, Telephone aerial, Aerial amplifier 2, Satellite aerial, Auxiliary heater aerial, Digital radio aerial...................................................................................................................................................................................................................................................12975
9. Chip card reader control unit, Control unit 1 for information electronics, Traffic data aerial.................................................................................................................................................................................................................................................................................................................................................................12976
10. Chip card reader control unit, Control unit 1 for information electronics, Traffic data aerial................................................................................................................................................................................................................................................................................................................................................................12977
078 -
TV tuner (MOST bus)............................................................................................................................................................................................................................................................................................................................................................................................................................................12978
1.
TV tuner (MOST bus)...........................................................................................................................................................................................................................................................................................................................................................................................................................................12978
2. Reversing camera system control unit, Control unit 1 for information electronics, TV tuner.....................................................................................................................................................................................................................................................................................................................................................................12979
3. Convenience system central control unit, Radio, Central locking and anti-theft alarm system aerial, TV tuner, Aerial amplifier 3...............................................................................................................................................................................................................................................................................................................................12980
4. Control unit 1 for information electronics, Radio, GPS aerial, Radio, telephone and navigation system aerial, Remote control receiver for auxiliary heater, TV tuner, Satellite aerial, Auxiliary heater aerial................................................................................................................................................................................................................................................12981
5. Radio, TV tuner, Aerial amplifier 2, Digital radio aerial, TV card reader......................................................................................................................................................................................................................................................................................................................................................................................12982
079 -
Preparation for mobile telephone (MOST bus) - USA..............................................................................................................................................................................................................................................................................................................................................................................................................12983
1.
Preparation for mobile telephone (MOST bus) - USA.............................................................................................................................................................................................................................................................................................................................................................................................................12983
2. Control unit 1 for information electronics, Microphone unit in front roof module...............................................................................................................................................................................................................................................................................................................................................................................12984
3. Control unit 1 for information electronics.....................................................................................................................................................................................................................................................................................................................................................................................................................12985
4. Control unit 1 for information electronics, GPS aerial, Radio, telephone and navigation system aerial, Telephone aerial, Telephone bracket, Satellite aerial...................................................................................................................................................................................................................................................................................................12986
080 -
Preparation for mobile telephone (MOST bus)....................................................................................................................................................................................................................................................................................................................................................................................................................12987
1.
Preparation for mobile telephone (MOST bus)...................................................................................................................................................................................................................................................................................................................................................................................................................12987
2. Central locking and anti-theft alarm system aerial, TV tuner, Aerial amplifier for mobile telephone, Aerial amplifier 3........................................................................................................................................................................................................................................................................................................................................12988
3. GPS aerial, Radio, telephone and navigation system aerial, Remote control receiver for auxiliary heater, Telephone aerial, TV tuner, Aerial amplifier for mobile telephone, Aerial amplifier 2, Satellite aerial, Auxiliary heater aerial, Digital radio aerial................................................................................................................................................................................................12989
4. Control unit 1 for information electronics, Aerial amplifier for mobile telephone, Telephone bracket...........................................................................................................................................................................................................................................................................................................................................................12990
5. Data bus diagnostic interface, Control unit 1 for information electronics, Aerial for Bluetooth, Microphone unit in front roof module..........................................................................................................................................................................................................................................................................................................................12991
081 -
Bluetooth car phone (MOST bus).................................................................................................................................................................................................................................................................................................................................................................................................................................12992
1.
Bluetooth car phone (MOST bus)................................................................................................................................................................................................................................................................................................................................................................................................................................12992
2. Control unit 1 for information electronics, Front left microphone, Front right microphone, Aerial for Bluetooth, Microphone unit in front roof module..........................................................................................................................................................................................................................................................................................................12993
3. Convenience system central control unit, Control unit 1 for information electronics, Radio, Central locking and anti-theft alarm system aerial, TV tuner, Aerial amplifier 3...................................................................................................................................................................................................................................................................................12994
4. Control unit 1 for information electronics, Radio, Radio, telephone and navigation system aerial, Remote control receiver for auxiliary heater, Telephone aerial, TV tuner, Aerial amplifier 2, Satellite aerial, Auxiliary heater aerial, Digital radio aerial................................................................................................................................................................................................12995
5. Onboard supply control unit, Control unit 1 for information electronics, Telephone bracket.....................................................................................................................................................................................................................................................................................................................................................................12996
082 -
Preparation for mobile telephone with no hands-free system (MOST bus)..........................................................................................................................................................................................................................................................................................................................................................................................12997
1.
Preparation for mobile telephone with no hands-free system (MOST bus).........................................................................................................................................................................................................................................................................................................................................................................................12997
2. Microphone unit in front roof module...........................................................................................................................................................................................................................................................................................................................................................................................................................12998
3. Control unit 1 for information electronics, GPS aerial, Radio, telephone and navigation system aerial, Telephone aerial, Satellite aerial, Auxiliary heater aerial.............................................................................................................................................................................................................................................................................................12999
083 -
Ring circuit break diagnostic..................................................................................................................................................................................................................................................................................................................................................................................................................................13000
1.
Ring circuit break diagnostic.................................................................................................................................................................................................................................................................................................................................................................................................................................13000
2. Digital sound package control unit, Data bus diagnostic interface, Control unit 1 for information electronics, Radio, CD changer, TV tuner, DVD changer........................................................................................................................................................................................................................................................................................................13001
084 -
Infotainment MOST bus..........................................................................................................................................................................................................................................................................................................................................................................................................................................13002
1.
Infotainment MOST bus.........................................................................................................................................................................................................................................................................................................................................................................................................................................13002
2. Digital sound package control unit, Data bus diagnostic interface, Control unit 1 for information electronics, Radio, CD changer, TV tuner, DVD changer........................................................................................................................................................................................................................................................................................................13003
085 -
CD/DVD changer (MOST bus)......................................................................................................................................................................................................................................................................................................................................................................................................................................13004
1.
CD/DVD changer (MOST bus).....................................................................................................................................................................................................................................................................................................................................................................................................................................13004
2. CD changer, DVD changer........................................................................................................................................................................................................................................................................................................................................................................................................................................13005
086 -
7-speed dual clutch gearbox 0B5 (S tronic).....................................................................................................................................................................................................................................................................................................................................................................................................................13006
1.
7-speed dual clutch gearbox 0B5 (S tronic)....................................................................................................................................................................................................................................................................................................................................................................................................................13006
2. Automatic gearbox control unit, Mechatronic unit for dual clutch gearbox.......................................................................................................................................................................................................................................................................................................................................................................................13007
3. Automatic gearbox control unit, Mechatronic unit for dual clutch gearbox, Cooling oil valve, Main pressure valve...............................................................................................................................................................................................................................................................................................................................................13008
4. Clutch temperature sender, Gearbox input speed sender 3, Automatic gearbox control unit, Mechatronic unit for dual clutch gearbox..............................................................................................................................................................................................................................................................................................................................13009
5. Gearbox input speed sender 2, Gearbox input speed sender 1, Gear sensor, Gearbox oil temperature sender 2, Automatic gearbox control unit, Mechatronic unit for dual clutch gearbox............................................................................................................................................................................................................................................................................13010
6. Automatic gearbox hydraulic pressure sender 1, Temperature sender in control unit, Automatic gearbox control unit, Mechatronic unit for dual clutch gearbox....................................................................................................................................................................................................................................................................................................13011
7. Gear selector position P switch, Automatic gearbox control unit, Selector lever sensors control unit, Mechatronic unit for dual clutch gearbox.................................................................................................................................................................................................................................................................................................................13012
087 -
4.2l petrol engine , CAUA......................................................................................................................................................................................................................................................................................................................................................................................................................................13013
1.
4.2l petrol engine , CAUA.....................................................................................................................................................................................................................................................................................................................................................................................................................................13013
2. Battery, Terminal 15 voltage supply relay, Battery monitor control unit........................................................................................................................................................................................................................................................................................................................................................................................13014
3. Battery isolation igniter, Jump start socket...................................................................................................................................................................................................................................................................................................................................................................................................................13015
4. Starter, Alternator, Voltage regulator, Terminal 30 wiring junction 2, Jump start socket.......................................................................................................................................................................................................................................................................................................................................................................13016
5. Main relay, Engine control unit, Engine component current supply relay.........................................................................................................................................................................................................................................................................................................................................................................................13017
6. Starter motor relay, Engine control unit, Starter motor relay 2................................................................................................................................................................................................................................................................................................................................................................................................13018
7. Engine control unit............................................................................................................................................................................................................................................................................................................................................................................................................................................13019
8. Engine control unit, Activated charcoal filter solenoid valve 1, Left electrohydraulic engine mounting solenoid valve, Fuel metering valve, Variable intake manifold changeover valve, Fuel metering valve 2, Fuel system diagnostic pump......................................................................................................................................................................................................................13020
9. Air mass meter, Secondary air pump relay, Engine control unit, Right electrohydraulic engine mounting solenoid valve, Secondary air pump motor.................................................................................................................................................................................................................................................................................................................13021
10. Additional coolant pump relay, Engine control unit, Camshaft control valve 1, Camshaft control valve 2, Exhaust camshaft control valve 1, Exhaust camshaft control valve 2, Continued coolant circulation pump................................................................................................................................................................................................................................................13022
11. Map-controlled engine cooling system thermostat, Engine control unit, Intake manifold flap valve, Intake manifold flap motor, Variable intake manifold motor..................................................................................................................................................................................................................................................................................................13023
12. Oil level and oil temperature sender, Brake servo relay, Engine control unit, Vacuum pump for brakes..........................................................................................................................................................................................................................................................................................................................................................13024
13. Engine control unit, Ignition coil 1 with output stage, Ignition coil 2 with output stage, Ignition coil 3 with output stage, Ignition coil 4 with output stage...............................................................................................................................................................................................................................................................................................13025
14. Engine control unit, Ignition coil 5 with output stage, Ignition coil 6 with output stage, Ignition coil 7 with output stage, Ignition coil 8 with output stage...............................................................................................................................................................................................................................................................................................13026
15. Knock sensor 1, Knock sensor 2, Knock sensor 3, Throttle valve module, Engine control unit....................................................................................................................................................................................................................................................................................................................................................................13027
16. Engine speed sender, Hall sender, Knock sensor 4, Hall sender 3, Engine control unit..........................................................................................................................................................................................................................................................................................................................................................................13028
17. Coolant temperature sender, Fuel pressure sender, Intake manifold flap potentiometer, Intake manifold flap potentiometer 2, Engine control unit...............................................................................................................................................................................................................................................................................................................13029
18. Accelerator position sender, Engine control unit..............................................................................................................................................................................................................................................................................................................................................................................................................13030
19. Hall sender 2, Brake servo pressure sensor, Hall sender 4, Fuel pressure sender for low-pressure, Engine control unit.........................................................................................................................................................................................................................................................................................................................................13031
20. Lambda probe, Lambda probe 2, Engine control unit.............................................................................................................................................................................................................................................................................................................................................................................................................13032
21. Lambda probe after catalytic converter, Lambda probe 2 after catalytic converter, Engine control unit.........................................................................................................................................................................................................................................................................................................................................................13033
22. Engine control unit, Injector, cylinder 1, Injector, cylinder 2, Injector, cylinder 6, Injector, cylinder 8...................................................................................................................................................................................................................................................................................................................................................13034
23. Engine control unit, Injector, cylinder 3, Injector, cylinder 4, Injector, cylinder 5, Injector, cylinder 7...................................................................................................................................................................................................................................................................................................................................................13035
24. Clutch position sender, Engine control unit...................................................................................................................................................................................................................................................................................................................................................................................................................13036
25. Brake light switch, Engine control unit.......................................................................................................................................................................................................................................................................................................................................................................................................................13037
26. Automatic gearbox control unit, Data bus diagnostic interface, Engine control unit............................................................................................................................................................................................................................................................................................................................................................................13038
27. Control unit in dash panel insert, Data bus diagnostic interface..............................................................................................................................................................................................................................................................................................................................................................................................13039
28. Fuel gauge sender, Fuel system pressurisation pump, Fuel gauge sender 2, Control unit in dash panel insert, Fuel pump control unit............................................................................................................................................................................................................................................................................................................................13040
29. Oil pressure switch, Gear detector switch, Coolant shortage indicator sender, Onboard supply control unit, Servotronic solenoid valve, Air conditioner compressor regulating valve............................................................................................................................................................................................................................................................................13041
088 -
Rear final drive - sport differential..........................................................................................................................................................................................................................................................................................................................................................................................................................13042
1.
Rear final drive - sport differential.........................................................................................................................................................................................................................................................................................................................................................................................................................13042
2. All-wheel drive control unit...................................................................................................................................................................................................................................................................................................................................................................................................................................13043
3. ABS control unit, All-wheel drive control unit.................................................................................................................................................................................................................................................................................................................................................................................................................13044
4. ESP sensor unit, ESP sensor unit 2, All-wheel drive control unit, Active steering control unit.................................................................................................................................................................................................................................................................................................................................................................13045
5. Oil pressure and oil temperature sender, Oil pressure and oil temperature sender 2, All-wheel drive control unit...............................................................................................................................................................................................................................................................................................................................................13046
6. All-wheel drive control unit, Clutch valve for all-wheel drive, Clutch valve 2 for all-wheel drive, All-wheel drive pump.......................................................................................................................................................................................................................................................................................................................................13047
7. All-wheel drive control unit, Connection 2 (running gear/dash panel insert CAN bus, high), in main wiring harness, Connection 2 (running gear/dash panel insert CAN bus, low), in main wiring harness..........................................................................................................................................................................................................................................................13048
089 -
Tail light cluster with LED, 2-door vehicle....................................................................................................................................................................................................................................................................................................................................................................................................................13049
1.
Tail light cluster with LED, 2-door vehicle...................................................................................................................................................................................................................................................................................................................................................................................................................13049
2. Left brake and tail light bulb.................................................................................................................................................................................................................................................................................................................................................................................................................................13050
3. Right brake and tail light bulb................................................................................................................................................................................................................................................................................................................................................................................................................................13051
090 -
Fuse assignment................................................................................................................................................................................................................................................................................................................................................................................................................................................13052
1.
Fuse assignment...............................................................................................................................................................................................................................................................................................................................................................................................................................................13052
2. Battery, Battery monitor control unit, Fuse 1 in fuse holder A.................................................................................................................................................................................................................................................................................................................................................................................................13053
3. Fuse 2 in fuse holder A, Fuse 3 in fuse holder A...............................................................................................................................................................................................................................................................................................................................................................................................................13054
4. Battery isolation igniter, Terminal 30 wiring junction 2, Jump start socket....................................................................................................................................................................................................................................................................................................................................................................................13055
5. Starter, Alternator, Terminal 30 wiring junction 2, Jump start socket..........................................................................................................................................................................................................................................................................................................................................................................................13056
6. Starter motor relay, Starter motor relay 2.....................................................................................................................................................................................................................................................................................................................................................................................................................13057
7. Fuse 1 on fuse holder B, Fuse carrier 1, Fuse 6 on fuse holder B...............................................................................................................................................................................................................................................................................................................................................................................................13058
8. Fuse carrier 1, Fuse 7 on fuse holder B, Fuse 12 on fuse holder B..............................................................................................................................................................................................................................................................................................................................................................................................13059
9. Fuse carrier 1, Fuse 13 on fuse holder B, Fuse 17 on fuse holder B.............................................................................................................................................................................................................................................................................................................................................................................................13060
10. Fuse holder C, Fuse carrier 1.................................................................................................................................................................................................................................................................................................................................................................................................................................13061
11. Fuse holder C, Fuse carrier 1.................................................................................................................................................................................................................................................................................................................................................................................................................................13062
12. Fuse holder C, Fuse carrier 1.................................................................................................................................................................................................................................................................................................................................................................................................................................13063
13. Fuse holder C, Fuse carrier 1.................................................................................................................................................................................................................................................................................................................................................................................................................................13064
14. Fuse holder C, Fuse carrier 2.................................................................................................................................................................................................................................................................................................................................................................................................................................13065
15. Fuse holder C, Fuse carrier 2.................................................................................................................................................................................................................................................................................................................................................................................................................................13066
16. Fuse holder C, Fuse carrier 2.................................................................................................................................................................................................................................................................................................................................................................................................................................13067
17. Fuse carrier 3, Fuse holder C.................................................................................................................................................................................................................................................................................................................................................................................................................................13068
18. Fuse holder C, Fuse carrier 3.................................................................................................................................................................................................................................................................................................................................................................................................................................13069
19. Fuse holder D, Fuse carrier 1.................................................................................................................................................................................................................................................................................................................................................................................................................................13070
20. Fuse holder D, Fuse carrier 1.................................................................................................................................................................................................................................................................................................................................................................................................................................13071
21. Fuse holder D, Fuse carrier 2.................................................................................................................................................................................................................................................................................................................................................................................................................................13072
22. Fuse holder D, Fuse carrier 2.................................................................................................................................................................................................................................................................................................................................................................................................................................13073
23. Fuse holder D, Fuse carrier 2.................................................................................................................................................................................................................................................................................................................................................................................................................................13074
24. Fuse holder F, Fuse carrier 1.................................................................................................................................................................................................................................................................................................................................................................................................................................13075
25. Fuse holder F, Fuse carrier 2.................................................................................................................................................................................................................................................................................................................................................................................................................................13076
26. Fuse holder F, Fuse carrier 2.................................................................................................................................................................................................................................................................................................................................................................................................................................13077
27. Fuse holder F, Fuse carrier 3.................................................................................................................................................................................................................................................................................................................................................................................................................................13078
28. Fuse holder F, Fuse carrier 3.................................................................................................................................................................................................................................................................................................................................................................................................................................13079
29. Fuse holder F, Fuse carrier 3.................................................................................................................................................................................................................................................................................................................................................................................................................................13080
30. Fuse holder F, Fuse carrier 4.................................................................................................................................................................................................................................................................................................................................................................................................................................13081
31. Fuse holder F, Fuse carrier 4.................................................................................................................................................................................................................................................................................................................................................................................................................................13082
32. Fuse holder F, Fuse carrier 4.................................................................................................................................................................................................................................................................................................................................................................................................................................13083
33. Fuse holder F, Fuse carrier 5.................................................................................................................................................................................................................................................................................................................................................................................................................................13084
34. Fuse holder F, Fuse carrier 5.................................................................................................................................................................................................................................................................................................................................................................................................................................13085
35. Fuse holder F, Fuse carrier 5.................................................................................................................................................................................................................................................................................................................................................................................................................................13086
091 -
Start/stop system..............................................................................................................................................................................................................................................................................................................................................................................................................................................13087
1.
Start/stop system.............................................................................................................................................................................................................................................................................................................................................................................................................................................13087
2. Voltage stabiliser.............................................................................................................................................................................................................................................................................................................................................................................................................................................13088
3. Relay for automatic anti-dazzle interior mirror................................................................................................................................................................................................................................................................................................................................................................................................................13089
4. Start/Stop operation button....................................................................................................................................................................................................................................................................................................................................................................................................................................13090
092 -
2.0l petrol engine with start/stop system , CDNB,CDNC..........................................................................................................................................................................................................................................................................................................................................................................................................13091
1.
2.0l petrol engine with start/stop system , CDNB,CDNC.........................................................................................................................................................................................................................................................................................................................................................................................................13091
2. Battery, Terminal 15 voltage supply relay......................................................................................................................................................................................................................................................................................................................................................................................................................13092
3. Battery isolation igniter, Terminal 30 wiring junction 2, Jump start socket....................................................................................................................................................................................................................................................................................................................................................................................13093
4. Starter, Alternator, Voltage regulator, Jump start socket......................................................................................................................................................................................................................................................................................................................................................................................................13094
5. Main relay, Engine component current supply relay..............................................................................................................................................................................................................................................................................................................................................................................................................13095
6. Starter motor relay, Starter motor relay 2, Fuse carrier 1.....................................................................................................................................................................................................................................................................................................................................................................................................13096
7. Oil level and oil temperature sender, Fuse carrier 1...........................................................................................................................................................................................................................................................................................................................................................................................................13097
8. Charge pressure control solenoid valve, Activated charcoal filter solenoid valve 1, Camshaft control valve 1, Turbocharger air recirculation valve.............................................................................................................................................................................................................................................................................................................13098
9. Left electrohydraulic engine mounting solenoid valve, Right electrohydraulic engine mounting solenoid valve, Climatronic coolant shut-off valve, Valve for oil pressure control................................................................................................................................................................................................................................................................................13099
10. Actuator 1 for camshaft adjustment, Continued coolant circulation pump........................................................................................................................................................................................................................................................................................................................................................................................13100
11. Actuator 6 for camshaft adjustment, Actuator 7 for camshaft adjustment, Actuator 8 for camshaft adjustment, Gear detection sensor.............................................................................................................................................................................................................................................................................................................................13101
12. Ignition coil 1 with output stage, Ignition coil 2 with output stage..........................................................................................................................................................................................................................................................................................................................................................................................13102
13. Ignition coil 3 with output stage, Ignition coil 4 with output stage..........................................................................................................................................................................................................................................................................................................................................................................................13103
14. Engine speed sender, Hall sender, Accelerator position sender, Accelerator position sender 2..................................................................................................................................................................................................................................................................................................................................................................13104
15. Fuel pressure sender, Throttle valve module...................................................................................................................................................................................................................................................................................................................................................................................................................13105
16. Oil pressure switch for reduced oil pressure, Intake manifold flap potentiometer..............................................................................................................................................................................................................................................................................................................................................................................13106
17. Air mass meter, Fuel pressure regulating valve................................................................................................................................................................................................................................................................................................................................................................................................................13107
18. Injector, cylinder 1, Injector, cylinder 2, Injector, cylinder 3, Injector, cylinder 4........................................................................................................................................................................................................................................................................................................................................................................13108
19. Lambda probe, Lambda probe after catalytic converter..........................................................................................................................................................................................................................................................................................................................................................................................................13109
20. Clutch position sender........................................................................................................................................................................................................................................................................................................................................................................................................................................13110
21. Brake light switch, Steering column electronics control unit..................................................................................................................................................................................................................................................................................................................................................................................................13111
22. Data bus diagnostic interface.................................................................................................................................................................................................................................................................................................................................................................................................................................13112
23. Control unit in dash panel insert, Data bus diagnostic interface..............................................................................................................................................................................................................................................................................................................................................................................................13113
24. Fuel gauge sender, Fuel system pressurisation pump, Control unit in dash panel insert, Fuel pump control unit.................................................................................................................................................................................................................................................................................................................................................13114
25. Oil pressure switch, Coolant shortage indicator sender, Onboard supply control unit...........................................................................................................................................................................................................................................................................................................................................................................13115
093 -
2.0l diesel engine with start/stop system , CAGA,CAGB,CAHA,CAHB................................................................................................................................................................................................................................................................................................................................................................................................13116
1.
2.0l diesel engine with start/stop system , CAGA,CAGB,CAHA,CAHB...............................................................................................................................................................................................................................................................................................................................................................................................13116
2. Battery, Terminal 15 voltage supply relay......................................................................................................................................................................................................................................................................................................................................................................................................................13117
3. Battery isolation igniter, Jump start socket...................................................................................................................................................................................................................................................................................................................................................................................................................13118
4. Starter, Alternator, Voltage regulator, Terminal 30 wiring junction 2, Jump start socket.......................................................................................................................................................................................................................................................................................................................................................................13119
5. Fuel pump relay, Terminal 30 voltage supply relay, Engine control unit.........................................................................................................................................................................................................................................................................................................................................................................................13120
6. Starter motor relay, Engine control unit, Starter motor relay 2................................................................................................................................................................................................................................................................................................................................................................................................13121
7. Automatic glow period control unit, Engine control unit........................................................................................................................................................................................................................................................................................................................................................................................................13122
8. Oil level and oil temperature sender, Engine control unit, Climatronic coolant shut-off valve, Pump for exhaust gas recirculation cooler.......................................................................................................................................................................................................................................................................................................................13123
9. Engine control unit, Charge pressure control solenoid valve, Heater element for crankcase breather, Left electrohydraulic engine mounting solenoid valve, Right electrohydraulic engine mounting solenoid valve, Air filter bypass flap valve, Exhaust gas recirculation cooler changeover valve, Coolant circulation pump.....................................................................................................................................13124
10. Low heat output relay, High heat output relay, Engine control unit, Auxiliary air heater element..............................................................................................................................................................................................................................................................................................................................................................13125
11. Accelerator position sender, Accelerator position sender 2, Engine control unit...............................................................................................................................................................................................................................................................................................................................................................................13126
12. Engine speed sender, Hall sender, Brake servo pressure sensor, Variable intake manifold position sender, Engine control unit, Variable intake manifold motor..................................................................................................................................................................................................................................................................................................13127
13. Throttle valve potentiometer, Exhaust gas recirculation potentiometer, Fuel pressure sender, Engine control unit, Exhaust gas recirculation valve, Intake manifold flap motor.................................................................................................................................................................................................................................................................................13128
14. Charge pressure sender, Intake air temperature sender, Fuel temperature sender, Exhaust gas pressure sensor 1, Position sender for charge pressure positioner, Gearbox neutral position sender, Engine control unit...........................................................................................................................................................................................................................................13129
15. Air mass meter, Engine control unit, Fuel pressure regulating valve, Fuel metering valve......................................................................................................................................................................................................................................................................................................................................................................13130
16. Coolant temperature sender, Radiator outlet coolant temperature sender, Exhaust gas temperature sender 1, Exhaust gas temperature sender 3, Exhaust gas temperature sender 4, Engine control unit.............................................................................................................................................................................................................................................................13131
17. Lambda probe, Engine control unit.............................................................................................................................................................................................................................................................................................................................................................................................................................13132
18. Engine control unit, Injector, cylinder 1, Injector, cylinder 2, Injector, cylinder 3, Injector, cylinder 4...................................................................................................................................................................................................................................................................................................................................................13133
19. Clutch position sender, Engine control unit...................................................................................................................................................................................................................................................................................................................................................................................................................13134
20. Brake light switch, Engine control unit, Supplementary fuel pump..............................................................................................................................................................................................................................................................................................................................................................................................13135
21. Data bus diagnostic interface, Engine control unit............................................................................................................................................................................................................................................................................................................................................................................................................13136
22. Control unit in dash panel insert, Data bus diagnostic interface..............................................................................................................................................................................................................................................................................................................................................................................................13137
23. Fuel gauge sender, Fuel system pressurisation pump, Control unit in dash panel insert.........................................................................................................................................................................................................................................................................................................................................................................13138
24. Oil pressure switch, Gear detector switch, Coolant shortage indicator sender, Onboard supply control unit, Servotronic solenoid valve, Air conditioner compressor regulating valve............................................................................................................................................................................................................................................................................13139
094 -
Rear lid and tail lights, 5-door vehicle.......................................................................................................................................................................................................................................................................................................................................................................................................................13140
1.
Rear lid and tail lights, 5-door vehicle......................................................................................................................................................................................................................................................................................................................................................................................................................13140
2. Convenience system central control unit, Left tail light, Left tail light 2, Luggage compartment light on left.................................................................................................................................................................................................................................................................................................................................................13141
3. Convenience system central control unit, Right tail light, Right tail light 2, Right luggage compartment light, Surround lighting 1 in rear lid................................................................................................................................................................................................................................................................................................................13142
4. Contact switch in lock cylinder for rear lid, anti-theft alarm system and central locking system, Release button for rear lid lock cylinder, Convenience system central control unit, Additional brake light bulb, Left number plate light, Right number pla e light...........................................................................................................................................................................................13143
5. Glass breakage sensor for rear window, Convenience system central control unit, Heated rear window.............................................................................................................................................................................................................................................................................................................................................................13144
095 -
Tail light cluster with LED, 5-door vehicle....................................................................................................................................................................................................................................................................................................................................................................................................................13145
1.
Tail light cluster with LED, 5-door vehicle...................................................................................................................................................................................................................................................................................................................................................................................................................13145
2. Convenience system central control unit........................................................................................................................................................................................................................................................................................................................................................................................................................13146
3. Convenience system central control unit........................................................................................................................................................................................................................................................................................................................................................................................................................13147
096 -
Electric sliding sunroof.......................................................................................................................................................................................................................................................................................................................................................................................................................................13148
1.
Electric sliding sunroof......................................................................................................................................................................................................................................................................................................................................................................................................................................13148
2. Sliding sunroof adjustment regulator, Sliding sunroof adjustment control unit, Convenience system central control unit, Sliding sunroof motor..................................................................................................................................................................................................................................................................................................................13149
097 -
Aerials, 5-door vehicle........................................................................................................................................................................................................................................................................................................................................................................................................................................13150
1.
Aerials, 5-door vehicle.......................................................................................................................................................................................................................................................................................................................................................................................................................................13150
2. GPS aerial, Telephone aerial, Auxiliary heater aerial, Roof aerial.............................................................................................................................................................................................................................................................................................................................................................................................13151
3. Aerial, Aerial amplifier, TV aerial 1, Aerial amplifier 4......................................................................................................................................................................................................................................................................................................................................................................................................13152
4. TV aerial 2, Aerial amplifier 3................................................................................................................................................................................................................................................................................................................................................................................................................................13153
5. Central locking and anti-theft alarm system aerial, Radio aerial 2, Aerial amplifier 2, Aerial amplifier 3, Digital radio aerial...............................................................................................................................................................................................................................................................................................................................13154
098 -
Adjustable driver and front passenger seats, 5-door vehicle....................................................................................................................................................................................................................................................................................................................................................................................................13155
1.
Adjustable driver and front passenger seats, 5-door vehicle...................................................................................................................................................................................................................................................................................................................................................................................................13155
2. Driver seat adjustment thermal fuse 1, Rear left footwell light................................................................................................................................................................................................................................................................................................................................................................................................13156
3. Driver seat lumbar support adjustment switch, Driver seat lumbar support longitudinal adjustment motor, Driver seat lumbar support height adjustment motor.....................................................................................................................................................................................................................................................................................................13157
4. Driver seat rake adjustment switch, Driver seat longitudinal adjustment switch, Driver seat longitudinal adjustment motor, Driver seat rake adjustment motor...................................................................................................................................................................................................................................................................................................13158
5. Driver seat backrest adjustment switch, Driver seat height adjustment switch, Driver seat backrest adjustment motor, Driver seat height adjustment motor.......................................................................................................................................................................................................................................................................................................13159
6. Front passenger seat adjustment thermal fuse 1, Rear right footwell light......................................................................................................................................................................................................................................................................................................................................................................................13160
7. Front passenger seat lumbar support adjustment switch, Front passenger seat lumbar support longitudinal adjustment motor, Front passenger seat lumbar support height adjustment motor..........................................................................................................................................................................................................................................................................13161
8. Front passenger seat longitudinal adjustment switch, Front passenger seat rake adjustment button, Front passenger seat longitudinal adjustment motor, Front passenger seat rake adjustment motor...............................................................................................................................................................................................................................................................13162
9. Front passenger seat backrest adjustment switch, Front passenger seat height adjustment switch, Front passenger seat backrest adjustment motor, Front passenger seat height adjustment motor...................................................................................................................................................................................................................................................................13163
099 -
Adjustable driver seat with memory function, seat ventilation and seat heating, 5-door vehicle.................................................................................................................................................................................................................................................................................................................................................................13164
1.
Adjustable driver seat with memory function, seat ventilation and seat heating, 5-door vehicle................................................................................................................................................................................................................................................................................................................................................................13164
2. Seat and steering column adjustment control unit with memory, Driver seat adjustment thermal fuse 1, Rear left footwell light..................................................................................................................................................................................................................................................................................................................................13165
3. Longitudinal adjustment sender for driver seat, Height adjustment sender for driver seat, Rake adjustment sender for driver seat, Seat and steering column adjustment control unit with memory, Driver seat longitudinal adjustment motor, Driver seat rake adjustment motor, Driver seat height adjustment motor..............................................................................................................................................13166
4. Head restraint height adjustment sender for driver seat, Backrest adjustment sender for driver seat, Seat and steering column adjustment control unit with memory, Driver seat backrest adjustment motor, Driver seat head restraint adjustment motor..........................................................................................................................................................................................................13167
5. Front left seat temperature sender, Seat and steering column adjustment control unit with memory, Heated seat cushion for driver seat, Heated backrest for driver seat, Driver seat cushion lateral support heater, Driver seat backrest lateral support hea er................................................................................................................................................................................................13168
6. Seat and steering column adjustment control unit with memory, Driver seat backrest fan, Driver seat cushion fan, Driver seat backrest fan 2, Driver seat cushion fan 2.........................................................................................................................................................................................................................................................................................13169
7. Driver seat lumbar support adjustment switch, Driver seat lumbar support longitudinal adjustment motor, Driver seat lumbar support height adjustment motor.....................................................................................................................................................................................................................................................................................................13170
8. Driver seat memory operating unit, Driver door control unit....................................................................................................................................................................................................................................................................................................................................................................................................13171
100 -
Ventilated seat with seat heating, 5-door vehicle..............................................................................................................................................................................................................................................................................................................................................................................................................13172
1.
Ventilated seat with seat heating, 5-door vehicle.............................................................................................................................................................................................................................................................................................................................................................................................................13172
2. Front left seat temperature sender, Control unit for front left seat ventilation, Fuse carrier 2, Fuse 5 on fuse holder C, Heated seat cushion for driver seat, Heated backrest for driver seat, Driver seat cushion lateral support heater, Driver seat backrest lateral support heater.......................................................................................................................................................................13173
3. Control unit for front left seat ventilation, Driver seat backrest fan, Driver seat cushion fan, Driver seat backrest fan 2, Driver seat cushion fan 2.........................................................................................................................................................................................................................................................................................................13174
4. Front right seat temperature sender, Control unit for front right seat ventilation, Heated seat cushion for front passenger seat, Front passenger seat lateral support heater, Front passenger seat backrest lateral support heater............................................................................................................................................................................................................................13175
5. Control unit for front right seat ventilation, Front passenger seat backrest fan, Front passenger seat cushion fan, Front passenger seat backrest fan 2, Front passenger seat cushion fan 2....................................................................................................................................................................................................................................................................13176
101 -
4.2l petrol engine , CFSA......................................................................................................................................................................................................................................................................................................................................................................................................................................13177
1.
4.2l petrol engine , CFSA.....................................................................................................................................................................................................................................................................................................................................................................................................................................13177
2. Battery, Terminal 15 voltage supply relay......................................................................................................................................................................................................................................................................................................................................................................................................................13178
3. Battery isolation igniter, Jump start socket...................................................................................................................................................................................................................................................................................................................................................................................................................13179
4. Starter, Alternator, Voltage regulator, Terminal 30 wiring junction 2, Jump start socket.......................................................................................................................................................................................................................................................................................................................................................................13180
5. Main relay, Engine control unit, Engine component current supply relay.........................................................................................................................................................................................................................................................................................................................................................................................13181
6. Starter motor relay, Engine control unit, Starter motor relay 2................................................................................................................................................................................................................................................................................................................................................................................................13182
7. Map-controlled engine cooling system thermostat, Engine control unit, Activated charcoal filter solenoid valve 1, Left electrohydraulic engine mounting solenoid valve, Right electrohydraulic engine mounting solenoid valve, Valve for oil pressure control..................................................................................................................................................................................................13183
8. Secondary air pump relay, Secondary air pump 2 relay, Engine control unit, Secondary air inlet valve, Intake manifold flap valve, Coolant circulation pump, Secondary air pump motor, Secondary air pump motor 2...............................................................................................................................................................................................................................................13184
9. Engine control unit, Ignition coil 1 with output stage, Ignition coil 2 with output stage, Ignition coil 3 with output stage, Ignition coil 4 with output stage................................................................................................................................................................................................................................................................................................13185
10. Engine control unit, Ignition coil 5 with output stage, Ignition coil 6 with output stage, Ignition coil 7 with output stage, Ignition coil 8 with output stage...............................................................................................................................................................................................................................................................................................13186
11. Knock sensor 1, Knock sensor 2, Knock sensor 3, Throttle valve module, Engine control unit....................................................................................................................................................................................................................................................................................................................................................................13187
12. Hall sender, Knock sensor 4, Throttle valve module 2, Engine control unit.....................................................................................................................................................................................................................................................................................................................................................................................13188
13. Intake manifold flap potentiometer, Intake manifold flap potentiometer 2, Engine control unit.................................................................................................................................................................................................................................................................................................................................................................13189
14. Engine speed sender, Hall sender 3, Engine control unit.......................................................................................................................................................................................................................................................................................................................................................................................................13190
15. Intake air temperature sender, Fuel pressure sender, Engine control unit......................................................................................................................................................................................................................................................................................................................................................................................13191
16. Engine control unit, Camshaft control valve 1, Exhaust flap valve, Exhaust camshaft control valve 1...........................................................................................................................................................................................................................................................................................................................................................13192
17. Lambda probe, Lambda probe 2, Engine control unit.............................................................................................................................................................................................................................................................................................................................................................................................................13193
18. Lambda probe after catalytic converter, Lambda probe 2 after catalytic converter, Engine control unit.........................................................................................................................................................................................................................................................................................................................................................13194
19. Accelerator position sender, Engine control unit..............................................................................................................................................................................................................................................................................................................................................................................................................13195
20. Engine control unit, Injector, cylinder 1, Injector, cylinder 2, Injector, cylinder 6, Injector, cylinder 8...................................................................................................................................................................................................................................................................................................................................................13196
21. Engine control unit, Injector, cylinder 3, Injector, cylinder 4, Injector, cylinder 5, Injector, cylinder 7...................................................................................................................................................................................................................................................................................................................................................13197
22. Engine control unit, Fuel metering valve, Fuel metering valve 2...............................................................................................................................................................................................................................................................................................................................................................................................13198
23. Oil level and oil temperature sender, Engine control unit, Vacuum pump for brakes.............................................................................................................................................................................................................................................................................................................................................................................13199
24. Oil pressure switch for reduced oil pressure, Oil temperature sender, Engine control unit.....................................................................................................................................................................................................................................................................................................................................................................13200
25. Brake light switch, Engine control unit, Fuel system diagnostic pump..........................................................................................................................................................................................................................................................................................................................................................................................13201
26. Data bus diagnostic interface, Engine control unit, Mechatronic unit for dual clutch gearbox..................................................................................................................................................................................................................................................................................................................................................................13202
27. Control unit in dash panel insert, Data bus diagnostic interface..............................................................................................................................................................................................................................................................................................................................................................................................13203
28. Fuel gauge sender, Fuel system pressurisation pump, Control unit in dash panel insert, Fuel pump control unit.................................................................................................................................................................................................................................................................................................................................................13204
29. Oil pressure switch, Coolant shortage indicator sender, Onboard supply control unit...........................................................................................................................................................................................................................................................................................................................................................................13205
102 -
Electrically adjustable rear spoiler...........................................................................................................................................................................................................................................................................................................................................................................................................................13206
1.
Electrically adjustable rear spoiler..........................................................................................................................................................................................................................................................................................................................................................................................................................13206
2. Rear spoiler adjustment limit switch 1, Rear spoiler adjustment limit switch 2, Adjustable rear spoiler control unit, Adjustable rear spoiler motor............................................................................................................................................................................................................................................................................................................13207
3. Adjustable rear spoiler switch, Adjustable rear spoiler control unit...........................................................................................................................................................................................................................................................................................................................................................................................13208
103 -
3.0l petrol engine , CAKA......................................................................................................................................................................................................................................................................................................................................................................................................................................13209
1.
3.0l petrol engine , CAKA.....................................................................................................................................................................................................................................................................................................................................................................................................................................13209
2. Battery, Terminal 15 voltage supply relay......................................................................................................................................................................................................................................................................................................................................................................................................................13210
3. Battery isolation igniter, Jump start socket...................................................................................................................................................................................................................................................................................................................................................................................................................13211
4. Starter, Alternator, Voltage regulator, Terminal 30 wiring junction 2, Jump start socket.......................................................................................................................................................................................................................................................................................................................................................................13212
5. Main relay, Engine component current supply relay..............................................................................................................................................................................................................................................................................................................................................................................................................13213
6. Starter motor relay, Starter motor relay 2.....................................................................................................................................................................................................................................................................................................................................................................................................................13214
7. Left electrohydraulic engine mounting solenoid valve, Camshaft control valve 1, Camshaft control valve 2, Climatronic coolant shut-off valve, Continued coolant circulation pump...............................................................................................................................................................................................................................................................................13215
8. Intake manifold flap potentiometer, Intake manifold flap potentiometer 2, Right electrohydraulic engine mounting solenoid valve................................................................................................................................................................................................................................................................................................................................13216
9. Activated charcoal filter solenoid valve 1, Secondary air inlet valve, Valve for oil pressure control..........................................................................................................................................................................................................................................................................................................................................................13217
10. Ignition coil 1 with output stage, Ignition coil 2 with output stage, Ignition coil 3 with output stage, Secondary air inlet valve 2..........................................................................................................................................................................................................................................................................................................................13218
11. Ignition coil 4 with output stage, Ignition coil 5 with output stage, Ignition coil 6 with output stage.......................................................................................................................................................................................................................................................................................................................................................13219
12. Oil pressure switch for reduced oil pressure, Knock sensor 1, Knock sensor 2..................................................................................................................................................................................................................................................................................................................................................................................13220
13. Accelerator position sender, Accelerator position sender 2....................................................................................................................................................................................................................................................................................................................................................................................................13221
14. Engine speed sender, Coolant temperature sender, Fuel pressure sender, Throttle valve module..................................................................................................................................................................................................................................................................................................................................................................13222
15. Hall sender, Hall sender 2, Intake manifold temperature sender 2..............................................................................................................................................................................................................................................................................................................................................................................................13223
16. Injector, cylinder 1, Injector, cylinder 2, Injector, cylinder 3, Injector, cylinder 4, Injector, cylinder 5, Injector, cylinder 6............................................................................................................................................................................................................................................................................................................................13224
17. Lambda probe, Lambda probe 2..................................................................................................................................................................................................................................................................................................................................................................................................................................13225
18. Lambda probe after catalytic converter, Lambda probe 2 after catalytic converter..............................................................................................................................................................................................................................................................................................................................................................................13226
19. Clutch position sender........................................................................................................................................................................................................................................................................................................................................................................................................................................13227
20. Brake light switch, Oil level and oil temperature sender, Steering column electronics control unit............................................................................................................................................................................................................................................................................................................................................................13228
21. Data bus diagnostic interface.................................................................................................................................................................................................................................................................................................................................................................................................................................13229
22. Control unit in dash panel insert, Data bus diagnostic interface..............................................................................................................................................................................................................................................................................................................................................................................................13230
23. Fuel gauge sender, Fuel system pressurisation pump, Control unit in dash panel insert, Fuel pump control unit.................................................................................................................................................................................................................................................................................................................................................13231
24. Oil pressure switch, Coolant shortage indicator sender, Onboard supply control unit...........................................................................................................................................................................................................................................................................................................................................................................13232
25. Coolant circulation pump......................................................................................................................................................................................................................................................................................................................................................................................................................................13233
104 -
Preparation for multimedia system..............................................................................................................................................................................................................................................................................................................................................................................................................................13234
1.
Preparation for multimedia system.............................................................................................................................................................................................................................................................................................................................................................................................................................13234
2. 2-pin connector................................................................................................................................................................................................................................................................................................................................................................................................................................................13235
105 -
Dynamic Ride Control...........................................................................................................................................................................................................................................................................................................................................................................................................................................13236
1.
Dynamic Ride Control..........................................................................................................................................................................................................................................................................................................................................................................................................................................13236
2. Adaptive suspension control unit...............................................................................................................................................................................................................................................................................................................................................................................................................................13237
3. Adaptive suspension control unit, Front left shock absorber damping adjustment valve, Front right shock absorber damping adjustment valve......................................................................................................................................................................................................................................................................................................................13238
4. Adaptive suspension control unit, Rear left shock absorber damping adjustment valve, Rear right shock absorber damping adjustment valve........................................................................................................................................................................................................................................................................................................................13239
106 -
8-speed automatic gearbox 0BK/0BL..............................................................................................................................................................................................................................................................................................................................................................................................................................13240
1.
8-speed automatic gearbox 0BK/0BL.............................................................................................................................................................................................................................................................................................................................................................................................................................13240
2. Gearbox oil temperature sender, Gearbox input speed sender, Gearbox output speed sender, Gear sensor, Automatic gearbox control unit...........................................................................................................................................................................................................................................................................................................................13241
3. Automatic gearbox control unit.................................................................................................................................................................................................................................................................................................................................................................................................................................13242
4. Automatic gearbox control unit, Onboard supply control unit, Selector lever sensors control unit, Solenoid valve 1, Automatic gearbox pressure regulating valve 1, Automatic gearbox pressure regulating valve 2, Automatic gearbox pressure regulating valve 3, Automatic gearbox pressure regulating valve 4, Automatic gearbox pressure regulating valve 5, Automatic gearbox pressure regulating valve 6, Automatic gearbox pressure regulating valve 7....13243
5. Gear selector position P switch, Automatic gearbox control unit, Selector lever sensors control unit, Selector lever lock solenoid.............................................................................................................................................................................................................................................................................................................................13244
107 -
Fuse assignment................................................................................................................................................................................................................................................................................................................................................................................................................................................13245
1.
Fuse assignment...............................................................................................................................................................................................................................................................................................................................................................................................................................................13245
2. Battery, Battery monitor control unit, Fuse holder A...........................................................................................................................................................................................................................................................................................................................................................................................................13246
3. ABS control unit fuse 1, Fuse holder A.........................................................................................................................................................................................................................................................................................................................................................................................................................13247
4. Battery isolation igniter, Engine glow plug strip fuse, Auxiliary heater fuse, Auxiliary heater fuse 2, Fuse holder A, Terminal 30 wiring junction 2...........................................................................................................................................................................................................................................................................................................13248
5. Starter, Alternator, Terminal 30 wiring junction 2.............................................................................................................................................................................................................................................................................................................................................................................................................13249
6. Starter motor relay, Starter motor relay 2.....................................................................................................................................................................................................................................................................................................................................................................................................................13250
7. Fuse holder B, Fuse carrier 1..................................................................................................................................................................................................................................................................................................................................................................................................................................13251
8. Fuse carrier 1.................................................................................................................................................................................................................................................................................................................................................................................................................................................13252
9. Fuse carrier 1.................................................................................................................................................................................................................................................................................................................................................................................................................................................13253
10. Fuse carrier 1................................................................................................................................................................................................................................................................................................................................................................................................................................................13254
11. Fuse carrier 1................................................................................................................................................................................................................................................................................................................................................................................................................................................13255
12. Fuse holder C, Fuse carrier 1.................................................................................................................................................................................................................................................................................................................................................................................................................................13256
13. Fuse carrier 1................................................................................................................................................................................................................................................................................................................................................................................................................................................13257
14. Fuse carrier 1................................................................................................................................................................................................................................................................................................................................................................................................................................................13258
15. Fuse carrier 1................................................................................................................................................................................................................................................................................................................................................................................................................................................13259
16. Fuse holder C, Fuse carrier 2.................................................................................................................................................................................................................................................................................................................................................................................................................................13260
17. Horn relay, Fuse carrier 2....................................................................................................................................................................................................................................................................................................................................................................................................................................13261
18. Fuse carrier 2................................................................................................................................................................................................................................................................................................................................................................................................................................................13262
19. Fuse carrier 3, Driver seat adjustment thermal fuse 1, Front passenger seat adjustment thermal fuse 1, Fuse holder C..........................................................................................................................................................................................................................................................................................................................................13263
20. Fuse carrier 3................................................................................................................................................................................................................................................................................................................................................................................................................................................13264
21. Fuse holder D, Fuse carrier 1.................................................................................................................................................................................................................................................................................................................................................................................................................................13265
22. Fuse carrier 1................................................................................................................................................................................................................................................................................................................................................................................................................................................13266
23. Fuse holder D, Fuse carrier 2.................................................................................................................................................................................................................................................................................................................................................................................................................................13267
24. Fuse carrier 2................................................................................................................................................................................................................................................................................................................................................................................................................................................13268
25. Fuse holder F, Fuse carrier 1.................................................................................................................................................................................................................................................................................................................................................................................................................................13269
26. Fuse holder F, Fuse carrier 2.................................................................................................................................................................................................................................................................................................................................................................................................................................13270
27. Fuse carrier 2................................................................................................................................................................................................................................................................................................................................................................................................................................................13271
28. Fuse holder F, Fuse carrier 3.................................................................................................................................................................................................................................................................................................................................................................................................................................13272
29. Fuse carrier 3................................................................................................................................................................................................................................................................................................................................................................................................................................................13273
30. Fuse carrier 3................................................................................................................................................................................................................................................................................................................................................................................................................................................13274
31. Fuse holder F, Fuse carrier 4.................................................................................................................................................................................................................................................................................................................................................................................................................................13275
32. Fuse carrier 4................................................................................................................................................................................................................................................................................................................................................................................................................................................13276
33. Voltage stabiliser, Relay for automatic anti-dazzle interior mirror, Fuse holder F, Fuse carrier 5............................................................................................................................................................................................................................................................................................................................................................13277
34. Fuse carrier 5................................................................................................................................................................................................................................................................................................................................................................................................................................................13278
35. Fuse carrier 5................................................................................................................................................................................................................................................................................................................................................................................................................................................13279
36. Relay for power sockets.......................................................................................................................................................................................................................................................................................................................................................................................................................................13280
108 -
1.8l petrol engine , CJEB,CJED,CJEE............................................................................................................................................................................................................................................................................................................................................................................................................................13281
1.
1.8l petrol engine , CJEB,CJED,CJEE...........................................................................................................................................................................................................................................................................................................................................................................................................................13281
2. Battery, Terminal 15 voltage supply relay......................................................................................................................................................................................................................................................................................................................................................................................................................13282
3. Battery isolation igniter, Terminal 30 wiring junction 2.......................................................................................................................................................................................................................................................................................................................................................................................................13283
4. Starter, Alternator, Voltage regulator, Terminal 30 wiring junction 2, Jump start socket.......................................................................................................................................................................................................................................................................................................................................................................13284
5. Main relay, Engine component current supply relay..............................................................................................................................................................................................................................................................................................................................................................................................................13285
6. Starter motor relay, Starter motor relay 2.....................................................................................................................................................................................................................................................................................................................................................................................................................13286
7. Activated charcoal filter solenoid valve 1, Left electrohydraulic engine mounting solenoid valve, Right electrohydraulic engine mounting solenoid valve, Camshaft control valve 1, Turbocharger air recirculation valve, Exhaust camshaft control valve 1......................................................................................................................................................................................................13287
8. Actuator 1 for camshaft adjustment, Valve for oil pressure control, Piston cooling jet control valve...........................................................................................................................................................................................................................................................................................................................................................13288
9. Actuator 6 for camshaft adjustment, Actuator 7 for camshaft adjustment, Actuator 8 for camshaft adjustment.....................................................................................................................................................................................................................................................................................................................................................13289
10. Oil pressure switch, Oil pressure switch for reduced oil pressure, Coolant temperature sender, Radiator outlet coolant temperature sender.....................................................................................................................................................................................................................................................................................................................13290
11. Ignition coil 1 with output stage, Ignition coil 2 with output stage, Ignition coil 3 with output stage, Ignition coil 4 with output stage....................................................................................................................................................................................................................................................................................................................13291
12. Accelerator position sender, Accelerator position sender 2....................................................................................................................................................................................................................................................................................................................................................................................................13292
13. Hall sender, Fuel pressure sender.............................................................................................................................................................................................................................................................................................................................................................................................................................13293
14. Engine speed sender, Throttle valve module....................................................................................................................................................................................................................................................................................................................................................................................................................13294
15. Intake manifold flap potentiometer............................................................................................................................................................................................................................................................................................................................................................................................................................13295
16. Gear detection sensor, Injector, cylinder 1, Injector, cylinder 2, Injector, cylinder 3, Injector, cylinder 4.................................................................................................................................................................................................................................................................................................................................................13296
17. Injector 2, cylinder 1, Injector 2, cylinder 2, Injector 2, cylinder 3, Injector 2, cylinder 4................................................................................................................................................................................................................................................................................................................................................................13297
18. Lambda probe, Lambda probe after catalytic converter, Fuel metering valve.....................................................................................................................................................................................................................................................................................................................................................................................13298
19. Clutch position sender........................................................................................................................................................................................................................................................................................................................................................................................................................................13299
20. Brake light switch, Steering column electronics control unit..................................................................................................................................................................................................................................................................................................................................................................................................13300
21. Data bus diagnostic interface.................................................................................................................................................................................................................................................................................................................................................................................................................................13301
22. Control unit in dash panel insert, Data bus diagnostic interface..............................................................................................................................................................................................................................................................................................................................................................................................13302
23. Control unit in dash panel insert, Fuel pump control unit.....................................................................................................................................................................................................................................................................................................................................................................................................13303
24. Coolant shortage indicator sender, Onboard supply control unit................................................................................................................................................................................................................................................................................................................................................................................................13304
109 -
2.0l diesel engine , CGLC,CGLD,CJCA,CJCB,CJCC,CMFA.............................................................................................................................................................................................................................................................................................................................................................................................................13305
1.
2.0l diesel engine , CGLC,CGLD,CJCA,CJCB,CJCC,CMFA............................................................................................................................................................................................................................................................................................................................................................................................................13305
2. Battery, Terminal 15 voltage supply relay......................................................................................................................................................................................................................................................................................................................................................................................................................13306
3. Battery isolation igniter, Terminal 30 wiring junction 2.......................................................................................................................................................................................................................................................................................................................................................................................................13307
4. Starter, Alternator, Voltage regulator, Terminal 30 wiring junction 2, Jump start socket.......................................................................................................................................................................................................................................................................................................................................................................13308
5. Terminal 30 voltage supply relay, Engine control unit..........................................................................................................................................................................................................................................................................................................................................................................................................13309
6. Starter motor relay, Engine control unit, Starter motor relay 2................................................................................................................................................................................................................................................................................................................................................................................................13310
7. Automatic glow period control unit, Engine control unit........................................................................................................................................................................................................................................................................................................................................................................................................13311
8. Oil level and oil temperature sender, Engine control unit, Climatronic coolant shut-off valve, Coolant circulation pump, Pump for exhaust gas recirculation cooler.............................................................................................................................................................................................................................................................................................13312
9. Engine control unit, Charge pressure control solenoid valve, Heater element for crankcase breather, Left electrohydraulic engine mounting solenoid valve, Air filter bypass flap valve, Exhaust gas recirculation cooler changeover valve......................................................................................................................................................................................................................13313
10. Low heat output relay, High heat output relay, Engine control unit, Auxiliary air heater element..............................................................................................................................................................................................................................................................................................................................................................13314
11. Accelerator position sender, Accelerator position sender 2, Engine control unit...............................................................................................................................................................................................................................................................................................................................................................................13315
12. Engine speed sender, Hall sender, Fuel pressure sender, Brake servo pressure sensor, Engine control unit......................................................................................................................................................................................................................................................................................................................................................13316
13. Throttle valve potentiometer, Fuel temperature sender, Exhaust gas recirculation potentiometer, Position sender for charge pressure positioner, Throttle valve module, Engine control unit, Exhaust gas recirculation control motor...........................................................................................................................................................................................................................13317
14. Charge pressure sender, Intake air temperature sender, Pressure differential sender, Gear detection sensor, Engine control unit...............................................................................................................................................................................................................................................................................................................................13318
15. Air mass meter, Engine control unit, Fuel pressure regulating valve, Fuel metering valve......................................................................................................................................................................................................................................................................................................................................................................13319
16. Coolant temperature sender, Radiator outlet coolant temperature sender, Exhaust gas temperature sender 1, Exhaust gas temperature sender 3, Exhaust gas temperature sender 4, Engine control unit.............................................................................................................................................................................................................................................................13320
17. Lambda probe, Engine control unit.............................................................................................................................................................................................................................................................................................................................................................................................................................13321
18. Engine control unit, Injector, cylinder 1, Injector, cylinder 2, Injector, cylinder 3, Injector, cylinder 4...................................................................................................................................................................................................................................................................................................................................................13322
19. NOx sender 2, Engine control unit, Control unit for NOx sender 2..............................................................................................................................................................................................................................................................................................................................................................................................13323
20. Engine control unit, Pump for reducing agent..................................................................................................................................................................................................................................................................................................................................................................................................................13324
21. Engine control unit, Control unit for reducing agent metering system..........................................................................................................................................................................................................................................................................................................................................................................................13325
22. Engine control unit, Control unit for reducing agent metering system, Heater for reducing-agent tank (heater circuit 1), Heater for reducing-agent line (heater circuit 2)....................................................................................................................................................................................................................................................................................13326
23. Tank sender for reducing agent, Temperature sender for reducing agent, Engine control unit, Control unit for reducing agent metering system...................................................................................................................................................................................................................................................................................................................13327
24. Clutch position sender, Engine control unit...................................................................................................................................................................................................................................................................................................................................................................................................................13328
25. Brake light switch, Oil pressure switch, Engine control unit..................................................................................................................................................................................................................................................................................................................................................................................................13329
26. Data bus diagnostic interface, Engine control unit............................................................................................................................................................................................................................................................................................................................................................................................................13330
27. Control unit in dash panel insert, Data bus diagnostic interface..............................................................................................................................................................................................................................................................................................................................................................................................13331
28. Fuel delivery unit, Fuel system pressurisation pump, Control unit in dash panel insert, Fuel pump control unit................................................................................................................................................................................................................................................................................................................................................13332
29. Coolant shortage indicator sender, Onboard supply control unit, Air conditioner compressor regulating valve...................................................................................................................................................................................................................................................................................................................................................13333
110 -
3.0l diesel engine , CDUC,CKVB,CKVC,CKVD,CLAB..................................................................................................................................................................................................................................................................................................................................................................................................................13334
1.
3.0l diesel engine , CDUC,CKVB,CKVC,CKVD,CLAB.................................................................................................................................................................................................................................................................................................................................................................................................................13334
2. Battery, Terminal 15 voltage supply relay......................................................................................................................................................................................................................................................................................................................................................................................................................13335
3. Battery isolation igniter, Terminal 30 wiring junction 2.......................................................................................................................................................................................................................................................................................................................................................................................................13336
4. Starter, Alternator, Voltage regulator, Terminal 30 wiring junction 2, Jump start socket.......................................................................................................................................................................................................................................................................................................................................................................13337
5. Terminal 30 voltage supply relay...............................................................................................................................................................................................................................................................................................................................................................................................................................13338
6. Starter motor relay, Starter motor relay 2.....................................................................................................................................................................................................................................................................................................................................................................................................................13339
7. Cylinder 2 combustion chamber pressure sender, Automatic glow period control unit..............................................................................................................................................................................................................................................................................................................................................................................13340
8. Oil pressure switch for reduced oil pressure, Oil level and oil temperature sender.............................................................................................................................................................................................................................................................................................................................................................................13341
9. Engine speed sender, Hall sender...............................................................................................................................................................................................................................................................................................................................................................................................................................13342
10. Left electrohydraulic engine mounting solenoid valve, Right electrohydraulic engine mounting solenoid valve...................................................................................................................................................................................................................................................................................................................................................13343
11. Low heat output relay, Auxiliary air heater element...........................................................................................................................................................................................................................................................................................................................................................................................................13344
12. Accelerator position sender, Accelerator position sender 2....................................................................................................................................................................................................................................................................................................................................................................................................13345
13. Brake servo pressure sensor, Temperature sender for engine temperature regulation.............................................................................................................................................................................................................................................................................................................................................................................13346
14. Throttle valve module.........................................................................................................................................................................................................................................................................................................................................................................................................................................13347
15. Fuel pressure sender, Turbocharger 1 control unit.............................................................................................................................................................................................................................................................................................................................................................................................................13348
16. Charge pressure sender, Intake air temperature sender, Air mass meter, Pressure differential sender...........................................................................................................................................................................................................................................................................................................................................................13349
17. Pump for reducing agent.......................................................................................................................................................................................................................................................................................................................................................................................................................................13350
18. Control unit for reducing agent metering system, Transfer pump for reducing agent.............................................................................................................................................................................................................................................................................................................................................................................13351
19. Control unit for reducing agent metering system, Heater for reducing agent tank (heater circuit 1), Heater for reducing agent line (heater circuit 2).........................................................................................................................................................................................................................................................................................................13352
20. Control unit for reducing agent metering system, Injector for reducing agent, Heater for reducing agent breather line.........................................................................................................................................................................................................................................................................................................................................13353
21. Coolant temperature sender, Fuel temperature sender, Radiator outlet coolant temperature sender...............................................................................................................................................................................................................................................................................................................................................................13354
22. Lambda probe, Lambda probe heater.............................................................................................................................................................................................................................................................................................................................................................................................................................13355
23. Injector, cylinder 1, Injector, cylinder 6....................................................................................................................................................................................................................................................................................................................................................................................................................13356
24. Clutch position sender........................................................................................................................................................................................................................................................................................................................................................................................................................................13357
25. Brake light switch............................................................................................................................................................................................................................................................................................................................................................................................................................................13358
26. Data bus diagnostic interface.................................................................................................................................................................................................................................................................................................................................................................................................................................13359
27. Control unit in dash panel insert, Data bus diagnostic interface..............................................................................................................................................................................................................................................................................................................................................................................................13360
28. Fuel delivery unit, Control unit in dash panel insert, Fuel pump control unit.................................................................................................................................................................................................................................................................................................................................................................................13361
29. Coolant shortage indicator sender, Onboard supply control unit................................................................................................................................................................................................................................................................................................................................................................................................13362
111 -
3.0l petrol engine , CGWC,CGXC,CHMB,CMUA,CTUB..................................................................................................................................................................................................................................................................................................................................................................................................................13363
1.
3.0l petrol engine , CGWC,CGXC,CHMB,CMUA,CTUB.................................................................................................................................................................................................................................................................................................................................................................................................................13363
2. Battery, Terminal 15 voltage supply relay......................................................................................................................................................................................................................................................................................................................................................................................................................13364
3. Battery isolation igniter, Terminal 30 wiring junction 2.......................................................................................................................................................................................................................................................................................................................................................................................................13365
4. Starter, Alternator, Voltage regulator, Terminal 30 wiring junction 2, Jump start socket.......................................................................................................................................................................................................................................................................................................................................................................13366
5. Main relay, Engine component current supply relay..............................................................................................................................................................................................................................................................................................................................................................................................................13367
6. Starter motor relay, Starter motor relay 2.....................................................................................................................................................................................................................................................................................................................................................................................................................13368
7. Oil pressure switch, Intake manifold flap potentiometer, Intake manifold flap potentiometer 2, Camshaft control valve 1, Camshaft control valve 2..............................................................................................................................................................................................................................................................................................................13369
8. Continued coolant circulation pump.............................................................................................................................................................................................................................................................................................................................................................................................................................13370
9. Activated charcoal filter solenoid valve 1, Secondary air inlet valve, Left electrohydraulic engine mounting solenoid valve, Right electrohydraulic engine mounting solenoid valve, Valve for oil pressure control.............................................................................................................................................................................................................................................13371
10. Ignition coil 1 with output stage, Ignition coil 2 with output stage, Ignition coil 3 with output stage, Secondary air inlet valve 2..........................................................................................................................................................................................................................................................................................................................13372
11. Ignition coil 4 with output stage, Ignition coil 5 with output stage, Ignition coil 6 with output stage.......................................................................................................................................................................................................................................................................................................................................................13373
12. Oil pressure switch for reduced oil pressure, Knock sensor 1, Knock sensor 2..................................................................................................................................................................................................................................................................................................................................................................................13374
13. Accelerator position sender, Accelerator position sender 2....................................................................................................................................................................................................................................................................................................................................................................................................13375
14. Engine speed sender, Hall sender, Coolant temperature sender, Fuel pressure sender, Throttle valve module.....................................................................................................................................................................................................................................................................................................................................................13376
15. Hall sender 2, Brake servo pressure sensor, Regulating flap control unit......................................................................................................................................................................................................................................................................................................................................................................................13377
16. Charge pressure sender, Intake manifold temperature sender 2, Charge pressure sender 2, Control unit for fuel tank leak detection.............................................................................................................................................................................................................................................................................................................................13378
17. Injector, cylinder 1, Injector, cylinder 2, Injector, cylinder 3, Injector, cylinder 4, Injector, cylinder 5, Injector, cylinder 6............................................................................................................................................................................................................................................................................................................................13379
18. Lambda probe, Lambda probe 2..................................................................................................................................................................................................................................................................................................................................................................................................................................13380
19. Lambda probe after catalytic converter, Lambda probe 2 after catalytic converter..............................................................................................................................................................................................................................................................................................................................................................................13381
20. Clutch position sender........................................................................................................................................................................................................................................................................................................................................................................................................................................13382
21. Brake light switch, Oil level and oil temperature sender, Steering column electronics control unit............................................................................................................................................................................................................................................................................................................................................................13383
22. Data bus diagnostic interface.................................................................................................................................................................................................................................................................................................................................................................................................................................13384
23. Control unit in dash panel insert, Data bus diagnostic interface..............................................................................................................................................................................................................................................................................................................................................................................................13385
24. Fuel delivery unit, Control unit in dash panel insert, Fuel pump control unit.................................................................................................................................................................................................................................................................................................................................................................................13386
25. Coolant shortage indicator sender, Onboard supply control unit................................................................................................................................................................................................................................................................................................................................................................................................13387
112 -
2.0l petrol engine , CADA,CAEB,CAED,CDNB,CDNC,CDZA,CFKA,CPMA,CPMB..............................................................................................................................................................................................................................................................................................................................................................................................13388
1.
2.0l petrol engine , CADA,CAEB,CAED,CDNB,CDNC,CDZA,CFKA,CPMA,CPMB.............................................................................................................................................................................................................................................................................................................................................................................................13388
2. Battery, Terminal 15 voltage supply relay......................................................................................................................................................................................................................................................................................................................................................................................................................13389
3. Battery isolation igniter, Terminal 30 wiring junction 2.......................................................................................................................................................................................................................................................................................................................................................................................................13390
4. Starter, Alternator, Voltage regulator, Terminal 30 wiring junction 2, Jump start socket.......................................................................................................................................................................................................................................................................................................................................................................13391
5. Main relay, Engine component current supply relay..............................................................................................................................................................................................................................................................................................................................................................................................................13392
6. Starter motor relay, Starter motor relay 2, Fuse carrier 1.....................................................................................................................................................................................................................................................................................................................................................................................................13393
7. Oil level and oil temperature sender, Fuse carrier 1, Coolant circulation pump.................................................................................................................................................................................................................................................................................................................................................................................13394
8. Charge pressure control solenoid valve, Activated charcoal filter solenoid valve 1, Camshaft control valve 1, Turbocharger air recirculation valve, Valve for oil pressure control.............................................................................................................................................................................................................................................................................13395
9. Fuel quality sender, Left electrohydraulic engine mounting solenoid valve, Right electrohydraulic engine mounting solenoid valve, Continued coolant circulation pump...........................................................................................................................................................................................................................................................................................13396
10. Actuator 1 for camshaft adjustment............................................................................................................................................................................................................................................................................................................................................................................................................................13397
11. Actuator 6 for camshaft adjustment, Actuator 7 for camshaft adjustment, Actuator 8 for camshaft adjustment, Brake servo pressure sensor, Gear detection sensor................................................................................................................................................................................................................................................................................................13398
12. Ignition coil 1 with output stage, Ignition coil 2 with output stage..........................................................................................................................................................................................................................................................................................................................................................................................13399
13. Engine speed sender, Ignition coil 3 with output stage, Ignition coil 4 with output stage.....................................................................................................................................................................................................................................................................................................................................................................13400
14. Engine speed sender, Hall sender, Accelerator position sender, Accelerator position sender 2..................................................................................................................................................................................................................................................................................................................................................................13401
15. Fuel pressure sender, Throttle valve module...................................................................................................................................................................................................................................................................................................................................................................................................................13402
16. Coolant temperature sender, Intake manifold flap potentiometer, Fuel pressure sender for low-pressure.........................................................................................................................................................................................................................................................................................................................................................13403
17. Oil pressure switch, Oil pressure switch for reduced oil pressure, Air mass meter, Tank pressure sensor, Control unit for fuel tank leak detection, Fuel pressure regulating valve............................................................................................................................................................................................................................................................................13404
18. Injector, cylinder 1, Injector, cylinder 2, Injector, cylinder 3, Injector, cylinder 4........................................................................................................................................................................................................................................................................................................................................................................13405
19. Lambda probe, Lambda probe after catalytic converter..........................................................................................................................................................................................................................................................................................................................................................................................................13406
20. Clutch position sender........................................................................................................................................................................................................................................................................................................................................................................................................................................13407
21. Brake light switch, Steering column electronics control unit..................................................................................................................................................................................................................................................................................................................................................................................................13408
22. Data bus diagnostic interface.................................................................................................................................................................................................................................................................................................................................................................................................................................13409
23. Control unit in dash panel insert, Data bus diagnostic interface..............................................................................................................................................................................................................................................................................................................................................................................................13410
24. Control unit in dash panel insert, Fuel pump control unit.....................................................................................................................................................................................................................................................................................................................................................................................................13411
25. Coolant shortage indicator sender, Onboard supply control unit................................................................................................................................................................................................................................................................................................................................................................................................13412
113 -
Basic equipment................................................................................................................................................................................................................................................................................................................................................................................................................................................13413
1.
Basic equipment...............................................................................................................................................................................................................................................................................................................................................................................................................................................13413
2. Entry and start authorisation switch, Fuse 6 on fuse holder D..................................................................................................................................................................................................................................................................................................................................................................................................13414
3. Control unit in dash panel insert, Radio controlled clock receiver, Radio controlled clock.....................................................................................................................................................................................................................................................................................................................................................................13415
4. Fuel delivery unit, Control unit in dash panel insert..........................................................................................................................................................................................................................................................................................................................................................................................................13416
5. Steering column electronics control unit.......................................................................................................................................................................................................................................................................................................................................................................................................................13417
6. Turn signal switch, Cruise control system switch, Steering column electronics control unit.....................................................................................................................................................................................................................................................................................................................................................................13418
7. Intermittent wiper switch, Switch module for driving mode selection, Start/Stop operation button, Onboard supply control unit, Steering column electronics control unit, Control unit for electronic steering column lock......................................................................................................................................................................................................................................13419
8. Bonnet contact switch, Treble horn, Bass horn, Horn relay, Onboard supply control unit.........................................................................................................................................................................................................................................................................................................................................................................13420
9. Rain and light sensor, Wiper motor control unit, Onboard supply control unit, Headlight washer system pump.....................................................................................................................................................................................................................................................................................................................................................13421
10. Front left brake pad wear sender, Front right brake pad wear sender, Rear right brake pad wear sender, Onboard supply control unit............................................................................................................................................................................................................................................................................................................................13422
11. Brake fluid level warning contact, Ambient temperature sensor, Coolant shortage indicator sender, Windscreen washer fluid level sender, Onboard supply control unit, Left washer jet heater element, Right washer jet heater element..........................................................................................................................................................................................................................13423
12. Air quality sensor, Refrigerant pressure and temperature sender, Onboard supply control unit, Garage door operation control unit..............................................................................................................................................................................................................................................................................................................................13424
13. Light switch, Hazard warning lights button, Onboard supply control unit.......................................................................................................................................................................................................................................................................................................................................................................................13425
14. Onboard supply control unit, Front left headlight.............................................................................................................................................................................................................................................................................................................................................................................................................13426
15. Onboard supply control unit, Front right headlight............................................................................................................................................................................................................................................................................................................................................................................................................13427
16. Rear left reading light button, Onboard supply control unit, Vanity mirror light bulb, Front interior light, Rear right interior light........................................................................................................................................................................................................................................................................................................................13428
17. Key operated switch to deactivate front passenger side airbag, Valet parking button, Onboard supply control unit, Valet parking warning lamp..................................................................................................................................................................................................................................................................................................................13429
18. Glove compartment light switch, Onboard supply control unit, Front left footwell illumination bulb, Front right footwell illumination bulb, Glove compartment light, Earth connection 4, in main wiring harness...............................................................................................................................................................................................................................................13430
19. Onboard supply control unit, Earth connection 4, in main wiring harness, Connection 26, in main wiring harness................................................................................................................................................................................................................................................................................................................................................13431
20. Adaptive cruise control unit, Onboard supply control unit.....................................................................................................................................................................................................................................................................................................................................................................................................13432
21. Rear roller blind switch, Button for TCS and electronic stabilisation program, Parking aid button, Onboard supply control unit................................................................................................................................................................................................................................................................................................................................13433
22. Entry and start authorisation button, Onboard supply control unit.............................................................................................................................................................................................................................................................................................................................................................................................13434
23. Entry and start authorisation button, Contact sensor for front left exterior door handle, Contact sensor for front right exterior door handle, Convenience system central control unit, Left aerial for entry and start authorisation.........................................................................................................................................................................................................................13435
24. Convenience system central control unit, Left tail light, Left tail light 2, Luggage compartment light........................................................................................................................................................................................................................................................................................................................................................13436
25. Convenience system central control unit, Rear lid central locking motor.......................................................................................................................................................................................................................................................................................................................................................................................13437
26. Convenience system central control unit, Right tail light, Right tail light 2.................................................................................................................................................................................................................................................................................................................................................................................13438
27. Button 1 for tilting roof, Sliding sunroof adjustment control unit, Convenience system central control unit, Sliding sunroof motor............................................................................................................................................................................................................................................................................................................................13439
28. Anti-theft alarm sensor, Alarm horn, Convenience system central control unit..................................................................................................................................................................................................................................................................................................................................................................................13440
29. Clutch pedal switch, Convenience system central control unit..................................................................................................................................................................................................................................................................................................................................................................................................13441
30. Brake light switch, Convenience system central control unit...................................................................................................................................................................................................................................................................................................................................................................................................13442
31. Convenience system central control unit.......................................................................................................................................................................................................................................................................................................................................................................................................................13443
32. Convenience system central control unit.......................................................................................................................................................................................................................................................................................................................................................................................................................13444
33. Convenience system central control unit, Relay for power sockets, Rear roller blind motor, Tank filler flap locking motor, Heated rear window.................................................................................................................................................................................................................................................................................................................13445
34. Relay for power sockets, Cigarette lighter, 12 V socket, DC/AC converter with socket, 12 V - 230 V, 12 V socket 2, 12 V socket 3..............................................................................................................................................................................................................................................................................................................................13446
114 -
Convenience system.............................................................................................................................................................................................................................................................................................................................................................................................................................................13447
1.
Convenience system............................................................................................................................................................................................................................................................................................................................................................................................................................................13447
2. Entry and start authorisation button, Convenience system central control unit, Luggage compartment aerial for entry and start system, Interior aerial 1 for entry and start system.............................................................................................................................................................................................................................................................................13448
3. Anti-theft alarm sensor, Alarm horn, Convenience system central control unit, Aerial amplifier 3...............................................................................................................................................................................................................................................................................................................................................................13449
4. Contact sensor for front left exterior door handle, Contact sensor for front right exterior door handle, Convenience system central control unit, Left aerial for entry and start authorisation................................................................................................................................................................................................................................................................13450
5. Contact sensor for rear left exterior door handle, Contact sensor for rear right exterior door handle, Convenience system central control unit.................................................................................................................................................................................................................................................................................................................13451
6. Window aerial suppression filter, Heated rear window relay, Convenience system central control unit, Heated rear window single fuse, Heated rear window........................................................................................................................................................................................................................................................................................................13452
7. Contact switch in lock cylinder for rear lid, anti-theft alarm system and central locking system, Release button for rear lid lock cylinder, Convenience system central control unit, Rear lid central locking motor, Left number plate light, Right number plate light........................................................................................................................................................................................13453
8. Driver door control unit.......................................................................................................................................................................................................................................................................................................................................................................................................................................13454
9. Operating unit for window regulator in driver door, Driver door control unit, Driver side window regulator motor...............................................................................................................................................................................................................................................................................................................................................13455
10. Driver side central locking lock unit, Driver door control unit...............................................................................................................................................................................................................................................................................................................................................................................................13456
11. Driver side interior locking switch, Rear lid remote release switch, Driver door control unit, Driver door opener illumination bulb, Driver side door warning lamp, Front left entry light....................................................................................................................................................................................................................................................................13457
12. Driver seat memory operating unit, Driver door control unit...................................................................................................................................................................................................................................................................................................................................................................................................13458
13. Driver seat memory operating unit, Driver door control unit...................................................................................................................................................................................................................................................................................................................................................................................................13459
14. Mirror adjustment switch, Mirror adjustment changeover switch, Adjustment switch for mirror with fold-in feature, Interior monitoring switch, Alarm system off switch, Driver door control unit, Central locking SAFELOCK function warning lamp...............................................................................................................................................................................................................13460
15. Potentiometer for horizontal adjustment of driver side mirror, Potentiometer for vertical adjustment of driver side mirror, Driver door control unit, Driver side mirror adjustment motor, Driver side fold-in mirror motor, Driver side mirror adjustment motor..............................................................................................................................................................................................13461
16. Driver door control unit, Lane change assist warning lamp in driver side exterior mirror, Driver side turn signal repeater bulb, Driver side entry light in exterior mirror, Driver side automatic anti-dazzle exterior mirror, Heated exterior mirror on d
iver side.........................................................................................................................................................................................13462
17. Front passenger door control unit.............................................................................................................................................................................................................................................................................................................................................................................................................................13463
18. Front passenger side central locking lock unit, Front passenger door control unit.............................................................................................................................................................................................................................................................................................................................................................................13464
19. Window regulator switch in front passenger door, Front passenger side interior locking switch, Front passenger door control unit, Front passenger side window regulator motor.................................................................................................................................................................................................................................................................................13465
20. Front passenger door control unit, Front passenger door opener illumination bulb, Front right entry light, Front passenger side door warning lamp.............................................................................................................................................................................................................................................................................................................13466
21. Potentiometer for horizontal adjustment of front passenger side mirror, Potentiometer for vertical adjustment of front passenger side mirror, Front passenger door control unit, Front passenger side mirror adjustment motor, Front passenger side fold-in mirror motor, Front passenger side mirror adjustment motor........................................................................................................................................13467
22. Front passenger door control unit, Lane change assist warning lamp in front passenger side exterior mirror, Front passenger side turn signal repeater bulb, Front passenger side entry light in exterior mirror, Front passenger side automatic anti-dazzle exterior mirror, Heated exterior mirror on front passenger side...................................................................................................................................13468
23. Rear left door control unit...................................................................................................................................................................................................................................................................................................................................................................................................................................13469
24. Rear left central locking lock unit, Rear left door control unit..............................................................................................................................................................................................................................................................................................................................................................................................13470
25. Rear left window regulator switch, in door, Rear left interior locking switch, Rear left door control unit, Rear left window regulator motor..................................................................................................................................................................................................................................................................................................................13471
26. Rear left door control unit, Rear left door opener illumination bulb, Rear left entry light, Rear left door warning lamp......................................................................................................................................................................................................................................................................................................................................13472
27. Rear right door control unit..................................................................................................................................................................................................................................................................................................................................................................................................................................13473
28. Rear right central locking lock unit, Rear right door control unit............................................................................................................................................................................................................................................................................................................................................................................................13474
29. Rear right window regulator switch, in door, Rear right interior locking switch, Rear right door control unit, Rear right window regulator motor..............................................................................................................................................................................................................................................................................................................13475
30. Rear right door control unit, Rear right door opener illumination bulb, Rear right entry light, Rear right door warning lamp..................................................................................................................................................................................................................................................................................................................................13476
115 -
Electromechanical steering.....................................................................................................................................................................................................................................................................................................................................................................................................................................13477
1.
Electromechanical steering....................................................................................................................................................................................................................................................................................................................................................................................................................................13477
2. Steering moment sender, Power steering control unit............................................................................................................................................................................................................................................................................................................................................................................................................13478
116 -
Interior mirror................................................................................................................................................................................................................................................................................................................................................................................................................................................13479
1.
Interior mirror...............................................................................................................................................................................................................................................................................................................................................................................................................................................13479
2. Interior mirror, Humidity sender, Rain and light sensor, Automatic anti-dazzle interior mirror.................................................................................................................................................................................................................................................................................................................................................................13480
3. Interior mirror, Main beam assist control unit, Automatic anti-dazzle interior mirror..........................................................................................................................................................................................................................................................................................................................................................................13481
4. Interior mirror, Driver door control unit, Front passenger door control unit, Automatic anti-dazzle interior mirror............................................................................................................................................................................................................................................................................................................................................13482
117 -
Gas discharge headlights with automatic headlight range control................................................................................................................................................................................................................................................................................................................................................................................................13483
1.
Gas discharge headlights with automatic headlight range control...............................................................................................................................................................................................................................................................................................................................................................................................13483
2. Light switch, Rear left vehicle level sender, Onboard supply control unit......................................................................................................................................................................................................................................................................................................................................................................................13484
3. Left gas discharge bulb control unit, Onboard supply control unit, Front left headlight, Left headlight range control motor, Left dip beam screen motor........................................................................................................................................................................................................................................................................................................13485
4. Onboard supply control unit, Left LED module for daytime running light and side light, Front left headlight....................................................................................................................................................................................................................................................................................................................................................13486
5. Right gas discharge bulb control unit, Onboard supply control unit, Right gas discharge (xenon) bulb, Front right headlight, Right headlight range control motor, Right dip beam screen motor..................................................................................................................................................................................................................................................................13487
6. Onboard supply control unit, Front right headlight, Front right turn signal bulb...............................................................................................................................................................................................................................................................................................................................................................................13488
118 -
Gas discharge headlights (bi-xenon) with automatic headlight range control and cornering light.................................................................................................................................................................................................................................................................................................................................................................13489
1.
Gas discharge headlights (bi-xenon) with automatic headlight range control and cornering light................................................................................................................................................................................................................................................................................................................................................................13489
2. Light switch, Rear left vehicle level sender, Onboard supply control unit......................................................................................................................................................................................................................................................................................................................................................................................13490
3. Onboard supply control unit, Output module for left headlight, Left gas discharge (xenon) bulb, Front left headlight, Left static cornering light, Left headlight range control motor, Left dip beam screen motor, Left dynamic cornering light control mo or..................................................................................................................................................................................................13491
4. Onboard supply control unit, Left LED module for daytime running light and side light, Front left headlight....................................................................................................................................................................................................................................................................................................................................................13492
5. Right gas discharge bulb control unit, Onboard supply control unit, Output module for right headlight, Right gas discharge (xenon) bulb, Front right headlight, Right static cornering light, Right headlight range control motor, Right dip beam screen motor, Right dynamic cornering light control motor....................................................................................................................................................13493
6. Onboard supply control unit, Front right headlight.............................................................................................................................................................................................................................................................................................................................................................................................................13494
119 -
Parking aid (PDC)..............................................................................................................................................................................................................................................................................................................................................................................................................................................13495
1.
Parking aid (PDC).............................................................................................................................................................................................................................................................................................................................................................................................................................................13495
2. Front left parking aid sender, Front parking aid warning buzzer, Onboard supply control unit...................................................................................................................................................................................................................................................................................................................................................................13496
3. Rear left parking aid sender, Rear right parking aid sender, Rear parking aid warning buzzer, Onboard supply control unit......................................................................................................................................................................................................................................................................................................................................13497
4. Parking aid button, Onboard supply control unit................................................................................................................................................................................................................................................................................................................................................................................................................13498
120 -
Lane departure warning.........................................................................................................................................................................................................................................................................................................................................................................................................................................13499
1.
Lane departure warning........................................................................................................................................................................................................................................................................................................................................................................................................................................13499
2. Data bus diagnostic interface, Lane departure warning control unit.............................................................................................................................................................................................................................................................................................................................................................................................13500
3. Lane departure warning control unit, Windscreen heater for lane departure warning..............................................................................................................................................................................................................................................................................................................................................................................13501
121 -
Lane change assist.............................................................................................................................................................................................................................................................................................................................................................................................................................................13502
1.
Lane change assist............................................................................................................................................................................................................................................................................................................................................................................................................................................13502
2. Lane change assist control unit................................................................................................................................................................................................................................................................................................................................................................................................................................13503
3. Lane change assist control unit 2..............................................................................................................................................................................................................................................................................................................................................................................................................................13504
4. Button for lane change assist, Lane change assist warning lamp in driver side exterior mirror, Lane change assist warning lamp in front passenger side exterior mirror.........................................................................................................................................................................................................................................................................................13505
122 -
Adaptive cruise control........................................................................................................................................................................................................................................................................................................................................................................................................................................13506
1.
Adaptive cruise control.......................................................................................................................................................................................................................................................................................................................................................................................................................................13506
2. Adaptive cruise control unit...................................................................................................................................................................................................................................................................................................................................................................................................................................13507
123 -
Airbag systems.................................................................................................................................................................................................................................................................................................................................................................................................................................................13508
1.
Airbag systems................................................................................................................................................................................................................................................................................................................................................................................................................................................13508
2. Airbag coil connector and return ring with slip ring, Airbag control unit, Driver side airbag igniter, Front passenger side airbag igniter 1, Front passenger side airbag igniter 2, Driver side airbag igniter 2..............................................................................................................................................................................................................................................13509
3. Airbag control unit, Driver side curtain airbag igniter, Front passenger side curtain airbag igniter, Battery isolation igniter................................................................................................................................................................................................................................................................................................................................13510
4. Driver side belt force limiter, Front passenger side belt force limiter, Airbag control unit, Driver seat belt tensioner igniter 1, Front passenger seat belt tensioner igniter 1, Rear belt tensioner igniter on driver side, Rear belt tensioner igniter o
front passenger side, Rear centre belt tensioner igniter.........................................................................................................................................13511
5. Side airbag crash sensor on driver side, Side airbag crash sensor on front passenger side, Rear side airbag crash sensor on driver side, Rear side airbag crash sensor on front passenger side, Front airbag crash sensor for driver side, Front airbag crash sensor for front passenger side, Airbag control unit.............................................................................................................................................13512
6. Airbag control unit, Side airbag igniter on driver side, Side airbag igniter on front passenger side, Rear side airbag igniter on driver side, Rear side airbag igniter on front passenger side................................................................................................................................................................................................................................................................13513
7. Key operated switch to deactivate front passenger side airbag, Airbag control unit, Front passenger side airbag deactivated warning lamp.......................................................................................................................................................................................................................................................................................................................13514
8. Driver side belt switch, Front passenger side belt switch, Seat occupied sensor, front passenger side, Driver side seat position sensor, Front passenger side seat position sensor, Airbag control unit........................................................................................................................................................................................................................................................13515
9. Front passenger side belt switch, Pressure sensor for seat occupied recognition, Seat belt force sensor for seat occupied recognition, Front passenger side seat position sensor, Airbag control unit, Seat occupied recognition control unit..................................................................................................................................................................................................................13516
10. Airbag control unit, Driver side knee airbag igniter, Front passenger side knee airbag igniter................................................................................................................................................................................................................................................................................................................................................................13517
11. Airbag control unit, Data bus diagnostic interface............................................................................................................................................................................................................................................................................................................................................................................................................13518
12. Control unit in dash panel insert, Data bus diagnostic interface, Airbag warning lamp.........................................................................................................................................................................................................................................................................................................................................................................13519
124 -
Automatic adaptive suspension, adjustable dampers..............................................................................................................................................................................................................................................................................................................................................................................................................13520
1.
Automatic adaptive suspension, adjustable dampers.............................................................................................................................................................................................................................................................................................................................................................................................................13520
2. Electronically controlled damping control unit.................................................................................................................................................................................................................................................................................................................................................................................................................13521
3. Front left body acceleration sender, Front right body acceleration sender, Rear body acceleration sender, Electronically controlled damping control unit.......................................................................................................................................................................................................................................................................................................13522
4. Rear left vehicle level sender, Rear right vehicle level sender, Front left vehicle level sender, Front right vehicle level sender, Electronically controlled damping control unit.............................................................................................................................................................................................................................................................................13523
5. Electronically controlled damping control unit, Front left shock absorber damping adjustment valve, Front right shock absorber damping adjustment valve, Rear left shock absorber damping adjustment valve, Rear right shock absorber damping adjustment valve.................................................................................................................................................................................................13524
6. Electronically controlled damping control unit, Data bus diagnostic interface..................................................................................................................................................................................................................................................................................................................................................................................13525
7. Switch module for driving mode selection, Start/Stop operation button, Onboard supply control unit, Data bus diagnostic interface..............................................................................................................................................................................................................................................................................................................................13526
125 -
Automatic air conditioning system, luxury Climatronic..........................................................................................................................................................................................................................................................................................................................................................................................................13527
1.
Automatic air conditioning system, luxury Climatronic.........................................................................................................................................................................................................................................................................................................................................................................................................13527
2. Fresh air blower control unit, Fresh air blower................................................................................................................................................................................................................................................................................................................................................................................................................13528
3. Sunlight penetration photosensor, Potentiometer for rear temperature selection.................................................................................................................................................................................................................................................................................................................................................................................13529
4. Defroster flap control motor, Right centre vent control motor..................................................................................................................................................................................................................................................................................................................................................................................................13530
5. Left footwell flap control motor, Left temperature flap control motor..........................................................................................................................................................................................................................................................................................................................................................................................13531
6. Left footwell vent temperature sender, Right footwell vent temperature sender, Evaporator output temperature sender, Air flow flap control motor, Air recirculation flap control motor.........................................................................................................................................................................................................................................................................13532
7. Ambient temperature sensor.....................................................................................................................................................................................................................................................................................................................................................................................................................................13533
8. Air quality sensor, Refrigerant pressure and temperature sender, Humidity sender in fresh air intake duct, Air conditioner compressor regulating valve.........................................................................................................................................................................................................................................................................................................13534
9. Convenience system central control unit, Frequency modulation (FM) frequency filter in negative wire, Frequency modulation (FM) frequency filter in positive wire, Heated rear window..........................................................................................................................................................................................................................................................................13535
10. Humidity sender, Convenience system central control unit, Automatic anti-dazzle interior mirror...............................................................................................................................................................................................................................................................................................................................................................13536
126 -
Automatic air conditioning system, basic Climatronic...........................................................................................................................................................................................................................................................................................................................................................................................................13537
1.
Automatic air conditioning system, basic Climatronic..........................................................................................................................................................................................................................................................................................................................................................................................................13537
2. Fresh air blower control unit..................................................................................................................................................................................................................................................................................................................................................................................................................................13538
3. Centre vent control motor......................................................................................................................................................................................................................................................................................................................................................................................................................................13539
4. Air recirculation flap control motor, Footwell flap control motor..............................................................................................................................................................................................................................................................................................................................................................................................13540
5. Centre vent temperature sender, Footwell vent temperature sender, Evaporator output temperature sender.........................................................................................................................................................................................................................................................................................................................................................13541
6. Refrigerant pressure and temperature sender, Humidity sender in fresh air intake duct, Air conditioner compressor regulating valve.............................................................................................................................................................................................................................................................................................................................13542
7. Frequency modulation (FM) frequency filter in negative wire, Frequency modulation (FM) frequency filter in positive wire, Heated rear window...................................................................................................................................................................................................................................................................................................................13543
127 -
Electromechanical parking brake................................................................................................................................................................................................................................................................................................................................................................................................................................13544
1.
Electromechanical parking brake...............................................................................................................................................................................................................................................................................................................................................................................................................................13544
2. Control unit for electromechanical parking brake...............................................................................................................................................................................................................................................................................................................................................................................................................13545
3. Electromechanical parking brake button, Auto-hold button, ABS control unit, Control unit for electromechanical parking brake...................................................................................................................................................................................................................................................................................................................................13546
4. Control unit for electromechanical parking brake, Left parking brake motor, Right parking brake motor, Connection 2 (running gear/dash panel insert CAN bus, high), in main wiring harness, Connection 2 (running gear/dash panel insert CAN bus, low), in main wiring harness.................................................................................................................................................................................13547
128 -
Trailer coupling...............................................................................................................................................................................................................................................................................................................................................................................................................................................13548
1.
Trailer coupling..............................................................................................................................................................................................................................................................................................................................................................................................................................................13548
2. Trailer detector control unit, Fuse carrier 2..................................................................................................................................................................................................................................................................................................................................................................................................................13549
3. Trailer detector control unit..................................................................................................................................................................................................................................................................................................................................................................................................................................13550
4. Trailer detector control unit, Trailer socket..................................................................................................................................................................................................................................................................................................................................................................................................................13551
129 -
Seat heating...................................................................................................................................................................................................................................................................................................................................................................................................................................................13552
1.
Seat heating..................................................................................................................................................................................................................................................................................................................................................................................................................................................13552
2. Heated driver seat regulator, Heated front passenger seat regulator, Onboard supply control unit, Heated seat cushion for driver seat, Heated backrest for driver seat.........................................................................................................................................................................................................................................................................................13553
3. Onboard supply control unit, Heated seat cushion for front passenger seat, Heated backrest for front passenger seat............................................................................................................................................................................................................................................................................................................................................13554
4. Seat heating control unit with regulator, Heated bench seat cushion for rear left seat, Heated bench seat cushion for rear right seat..........................................................................................................................................................................................................................................................................................................................13555
130 -
Preparation for multimedia system..............................................................................................................................................................................................................................................................................................................................................................................................................................13556
1.
Preparation for multimedia system.............................................................................................................................................................................................................................................................................................................................................................................................................................13556
2. 2-pin connector................................................................................................................................................................................................................................................................................................................................................................................................................................................13557
131 -
Dynamic Ride Control...........................................................................................................................................................................................................................................................................................................................................................................................................................................13558
1.
Dynamic Ride Control..........................................................................................................................................................................................................................................................................................................................................................................................................................................13558
2. Adaptive suspension control unit...............................................................................................................................................................................................................................................................................................................................................................................................................................13559
3. Adaptive suspension control unit, Front left shock absorber damping adjustment valve, Front right shock absorber damping adjustment valve......................................................................................................................................................................................................................................................................................................................13560
4. Adaptive suspension control unit, Rear left shock absorber damping adjustment valve, Rear right shock absorber damping adjustment valve........................................................................................................................................................................................................................................................................................................................13561
132 -
Anti-lock brake system (ABS) with electronic stabilisation program (ESP).......................................................................................................................................................................................................................................................................................................................................................................................13562
1.
Anti-lock brake system (ABS) with electronic stabilisation program (ESP)......................................................................................................................................................................................................................................................................................................................................................................................13562
2. Auto-hold button, ABS control unit, ABS control unit fuse 1....................................................................................................................................................................................................................................................................................................................................................................................................13563
3. TCS and ESP button, ABS control unit...........................................................................................................................................................................................................................................................................................................................................................................................................................13564
4. ESP sensor unit, ESP sensor unit 2, ABS control unit, Active steering control unit, ABS hydraulic pump.........................................................................................................................................................................................................................................................................................................................................................13565
5. Rear right speed sensor, Front right speed sensor, Rear left speed sensor, Front left speed sensor, ABS control unit...........................................................................................................................................................................................................................................................................................................................................13566
6. Brake light switch, ABS control unit, Convenience system central control unit, ABS hydraulic unit, Front right ABS inlet valve, Front right ABS outlet valve, Front left ABS inlet valve, Front left ABS outlet valve, Rear right ABS inlet valve, Rear left ABS inlet valve, Rear right ABS outlet valve, Rear left ABS outlet valve..........................................................................................................................13567
7. Steering angle sender, ABS control unit, Steering column electronics control unit, ABS hydraulic unit, Vehicle stabilization program switch valve 1, Vehicle stabilization program switch valve 2, Vehicle stabilization program high-pressure valve 1, Vehicle stabilization program high-pressure valve 2....................................................................................................................................................13568
8. Control unit in dash panel insert, Data bus diagnostic interface, ABS warning lamp, ESP and TCS warning lamp...................................................................................................................................................................................................................................................................................................................................................13569
133 -
Ventilated seat with seat heating, 5-door vehicle..............................................................................................................................................................................................................................................................................................................................................................................................................13570
1.
Ventilated seat with seat heating, 5-door vehicle.............................................................................................................................................................................................................................................................................................................................................................................................................13570
2. Front left seat temperature sender, Control unit for front left seat ventilation, Fuse carrier 2, Fuse 5 on fuse holder C, Heated seat cushion for driver seat, Heated backrest for driver seat, Driver seat cushion lateral support heater....................................................................................................................................................................................................................13571
3. Control unit for front left seat ventilation, Driver seat backrest fan, Driver seat cushion fan, Driver seat backrest fan 2, Driver seat cushion fan 2.........................................................................................................................................................................................................................................................................................................13572
4. Front right seat temperature sender, Control unit for front right seat ventilation, Heated seat cushion for front passenger seat, Heated backrest for front passenger seat, Front passenger seat lateral support heater........................................................................................................................................................................................................................................13573
5. Control unit for front right seat ventilation, Front passenger seat backrest fan, Front passenger seat cushion fan, Front passenger seat backrest fan 2, Front passenger seat cushion fan 2....................................................................................................................................................................................................................................................................13574
134 -
Tail light cluster with LED, 5-door vehicle....................................................................................................................................................................................................................................................................................................................................................................................................................13575
1.
Tail light cluster with LED, 5-door vehicle...................................................................................................................................................................................................................................................................................................................................................................................................................13575
2. Convenience system central control unit, Left tail light, Left tail light 2....................................................................................................................................................................................................................................................................................................................................................................................13576
3. Convenience system central control unit, Right tail light, Right tail light 2..................................................................................................................................................................................................................................................................................................................................................................................13577
135 -
Rear lid and tail lights, 5-door vehicle.......................................................................................................................................................................................................................................................................................................................................................................................................................13578
1.
Rear lid and tail lights, 5-door vehicle......................................................................................................................................................................................................................................................................................................................................................................................................................13578
2. Convenience system central control unit, Left tail light, Left tail light 2, Luggage compartment light on left.................................................................................................................................................................................................................................................................................................................................................13579
3. Convenience system central control unit, Right tail light, Right tail light 2, Right luggage compartment light, Surround lighting 1 in rear lid................................................................................................................................................................................................................................................................................................................13580
4. Contact switch in lock cylinder for rear lid, anti-theft alarm system and central locking system, Release button for rear lid lock cylinder, Convenience system central control unit, Left number plate light, Right number plate light........................................................................................................................................................................................................................13581
5. Glass breakage sensor for rear window, Convenience system central control unit, Additional brake light bulb, Heated rear window................................................................................................................................................................................................................................................................................................................................13582
136 -
Start/stop system..............................................................................................................................................................................................................................................................................................................................................................................................................................................13583
1.
Start/stop system.............................................................................................................................................................................................................................................................................................................................................................................................................................................13583
2. Voltage stabiliser.............................................................................................................................................................................................................................................................................................................................................................................................................................................13584
3. Fuse holder F, Fuse carrier 5..................................................................................................................................................................................................................................................................................................................................................................................................................................13585
4. Start/Stop operation button....................................................................................................................................................................................................................................................................................................................................................................................................................................13586
137 -
Tail light cluster with LED, 2-door vehicle....................................................................................................................................................................................................................................................................................................................................................................................................................13587
1.
Tail light cluster with LED, 2-door vehicle...................................................................................................................................................................................................................................................................................................................................................................................................................13587
2. Left tail light, Left tail light 2.............................................................................................................................................................................................................................................................................................................................................................................................................................13588
3. Right tail light, Right tail light 2...........................................................................................................................................................................................................................................................................................................................................................................................................................13589
138 -
Rear final drive - sport differential..........................................................................................................................................................................................................................................................................................................................................................................................................................13590
1.
Rear final drive - sport differential.........................................................................................................................................................................................................................................................................................................................................................................................................................13590
2. All-wheel drive control unit...................................................................................................................................................................................................................................................................................................................................................................................................................................13591
3. ABS control unit, All-wheel drive control unit.................................................................................................................................................................................................................................................................................................................................................................................................................13592
4. ESP sensor unit, ESP sensor unit 2, All-wheel drive control unit, Active steering control unit.................................................................................................................................................................................................................................................................................................................................................................13593
5. Oil pressure and oil temperature sender, Oil pressure and oil temperature sender 2, All-wheel drive control unit...............................................................................................................................................................................................................................................................................................................................................13594
6. All-wheel drive control unit, Clutch valve for all-wheel drive, Clutch valve 2 for all-wheel drive, All-wheel drive pump.......................................................................................................................................................................................................................................................................................................................................13595
7. All-wheel drive control unit, Connection 2 (running gear/dash panel insert CAN bus, high), in main wiring harness, Connection 2 (running gear/dash panel insert CAN bus, low), in main wiring harness..........................................................................................................................................................................................................................................................13596
139 -
Bluetooth car phone (MOST bus).................................................................................................................................................................................................................................................................................................................................................................................................................................13597
1.
Bluetooth car phone (MOST bus)................................................................................................................................................................................................................................................................................................................................................................................................................................13597
2. Control unit 1 for information electronics, Front left microphone, Front right microphone, Aerial for Bluetooth, Microphone unit in front roof module..........................................................................................................................................................................................................................................................................................................13598
3. Convenience system central control unit, Control unit 1 for information electronics, Radio, Central locking and anti-theft alarm system aerial, TV tuner, Aerial amplifier 3...................................................................................................................................................................................................................................................................................13599
4. Control unit 1 for information electronics, Radio, Radio, telephone and navigation system aerial, Remote control receiver for auxiliary heater, Telephone aerial, TV tuner, Aerial amplifier 2, Satellite aerial, Auxiliary heater aerial, Digital radio aerial................................................................................................................................................................................................13600
5. Onboard supply control unit, Control unit 1 for information electronics, Telephone bracket.....................................................................................................................................................................................................................................................................................................................................................................13601
140 -
Preparation for mobile telephone (infotainment CAN bus)........................................................................................................................................................................................................................................................................................................................................................................................................13602
1.
Preparation for mobile telephone (infotainment CAN bus).......................................................................................................................................................................................................................................................................................................................................................................................................13602
2. Radio, telephone and navigation system aerial, Remote control receiver for auxiliary heater, Telephone aerial, Aerial amplifier for mobile telephone, Auxiliary heater aerial..................................................................................................................................................................................................................................................................................13603
3. Telephone transmitter and receiver unit, Aerial amplifier for mobile telephone, Aerial for Bluetooth...........................................................................................................................................................................................................................................................................................................................................................13604
4. Radio, Telephone transmitter and receiver unit, Front left microphone, Microphone unit in front roof module....................................................................................................................................................................................................................................................................................................................................................13605
5. Telephone transmitter and receiver unit, Telephone bracket.....................................................................................................................................................................................................................................................................................................................................................................................................13606
141 -
Preparation for mobile telephone (MOST bus)....................................................................................................................................................................................................................................................................................................................................................................................................................13607
1.
Preparation for mobile telephone (MOST bus)...................................................................................................................................................................................................................................................................................................................................................................................................................13607
2. Central locking and anti-theft alarm system aerial, TV tuner, Aerial amplifier 3...............................................................................................................................................................................................................................................................................................................................................................................13608
3. GPS aerial, Radio, telephone and navigation system aerial, Remote control receiver for auxiliary heater, Telephone aerial, TV tuner, Aerial amplifier for mobile telephone, Aerial amplifier 2, Satellite aerial, Auxiliary heater aerial, Digital radio aerial................................................................................................................................................................................................13609
4. Control unit 1 for information electronics, Aerial amplifier for mobile telephone, Telephone bracket...........................................................................................................................................................................................................................................................................................................................................................13610
5. Data bus diagnostic interface, Control unit 1 for information electronics, Aerial for Bluetooth, Microphone unit in front roof module..........................................................................................................................................................................................................................................................................................................................13611
142 -
Radio with basic and basic plus sound system...................................................................................................................................................................................................................................................................................................................................................................................................................13612
1.
Radio with basic and basic plus sound system..................................................................................................................................................................................................................................................................................................................................................................................................................13612
2. Radio, Telephone transmitter and receiver unit.................................................................................................................................................................................................................................................................................................................................................................................................................13613
3. Data bus diagnostic interface, Display unit for front information display and operating unit control unit, Radio...............................................................................................................................................................................................................................................................................................................................................13614
4. Display unit for front information display and operating unit control unit, Radio..............................................................................................................................................................................................................................................................................................................................................................................13615
5. Radio, Front left treble loudspeaker, Front right treble loudspeaker, Front left mid-range and bass loudspeaker, Front right mid-range and bass loudspeaker....................................................................................................................................................................................................................................................................................................13616
6. Radio, Rear left treble loudspeaker, Rear right treble loudspeaker, Rear left mid-range and bass loudspeaker, Rear right mid-range and bass loudspeaker........................................................................................................................................................................................................................................................................................................13617
7. Radio, Radio, telephone and navigation system aerial, Aerial amplifier 2, Aerial amplifier 3, Satellite aerial.................................................................................................................................................................................................................................................................................................................................................13618
8. Radio, Connection for external audio sources...................................................................................................................................................................................................................................................................................................................................................................................................................13619
9. Radio, Connection for external audio sources...................................................................................................................................................................................................................................................................................................................................................................................................................13620
143 -
Radio with Standard sound system...............................................................................................................................................................................................................................................................................................................................................................................................................................13621
1.
Radio with Standard sound system..............................................................................................................................................................................................................................................................................................................................................................................................................................13621
2. Radio, Telephone transmitter and receiver unit.................................................................................................................................................................................................................................................................................................................................................................................................................13622
3. Display unit for front information display and operating unit control unit, Radio..............................................................................................................................................................................................................................................................................................................................................................................13623
4. Digital sound package control unit, Data bus diagnostic interface, Radio.......................................................................................................................................................................................................................................................................................................................................................................................13624
5. Digital sound package control unit, Radio, Front left treble loudspeaker, Front left mid-range and bass loudspeaker............................................................................................................................................................................................................................................................................................................................................13625
6. Digital sound package control unit, Radio, Front right treble loudspeaker, Front right mid-range and bass loudspeaker, Centre mid-range and treble loudspeaker.................................................................................................................................................................................................................................................................................................13626
7. Digital sound package control unit, Radio, Rear left treble loudspeaker, Rear right treble loudspeaker, Subwoofer in rear shelf, Rear left mid-range and bass loudspeaker, Rear right mid-range and bass loudspeaker...........................................................................................................................................................................................................................................13627
8. Radio, Radio, telephone and navigation system aerial, Aerial amplifier 2, Aerial amplifier 3, Satellite aerial.................................................................................................................................................................................................................................................................................................................................................13628
9. Radio, Connection for external audio sources...................................................................................................................................................................................................................................................................................................................................................................................................................13629
10. Radio, Connection for external audio sources..................................................................................................................................................................................................................................................................................................................................................................................................................13630
144 -
Radio with Bang & Olufsen sound system.........................................................................................................................................................................................................................................................................................................................................................................................................................13631
1.
Radio with Bang & Olufsen sound system........................................................................................................................................................................................................................................................................................................................................................................................................................13631
2. Radio, Telephone transmitter and receiver unit.................................................................................................................................................................................................................................................................................................................................................................................................................13632
3. Display unit for front information display and operating unit control unit, Radio..............................................................................................................................................................................................................................................................................................................................................................................13633
4. Digital sound package control unit, Data bus diagnostic interface, Radio.......................................................................................................................................................................................................................................................................................................................................................................................13634
5. Digital sound package control unit, Radio, Microphone unit in front roof module................................................................................................................................................................................................................................................................................................................................................................................13635
6. Digital sound package control unit, Radio, Front left treble loudspeaker, Front left bass loudspeaker, Front left mid-range loudspeaker, Centre mid-range and treble loudspeaker...............................................................................................................................................................................................................................................................................13636
7. Digital sound package control unit, Radio, Front right treble loudspeaker, Front right bass loudspeaker, Front right mid-range loudspeaker.....................................................................................................................................................................................................................................................................................................................13637
8. Digital sound package control unit, Radio, Rear left treble loudspeaker, Rear right treble loudspeaker, Rear left mid-range and bass loudspeaker, Rear right mid-range and bass loudspeaker....................................................................................................................................................................................................................................................................13638
9. Digital sound package control unit, Radio, Rear left mid-range loudspeaker, Subwoofer in rear shelf............................................................................................................................................................................................................................................................................................................................................................13639
10. Radio, Radio, telephone and navigation system aerial, Aerial amplifier 2, Aerial amplifier 3, Satellite aerial................................................................................................................................................................................................................................................................................................................................................13640
11. Radio, Connection for external audio sources..................................................................................................................................................................................................................................................................................................................................................................................................................13641
12. Radio, Connection for external audio sources..................................................................................................................................................................................................................................................................................................................................................................................................................13642
145 -
Actuator for structure-borne sound.............................................................................................................................................................................................................................................................................................................................................................................................................................13643
1.
Actuator for structure-borne sound............................................................................................................................................................................................................................................................................................................................................................................................................................13643
2. Control unit for structure-borne sound, Actuator for structure-borne sound.....................................................................................................................................................................................................................................................................................................................................................................................13644
146 -
MMI with radio and basic sound system..........................................................................................................................................................................................................................................................................................................................................................................................................................13645
1.
MMI with radio and basic sound system.........................................................................................................................................................................................................................................................................................................................................................................................................................13645
2. Radio..........................................................................................................................................................................................................................................................................................................................................................................................................................................................13646
3. Radio, Front left treble loudspeaker, Front right treble loudspeaker, Front left mid-range and bass loudspeaker, Front right mid-range and bass loudspeaker....................................................................................................................................................................................................................................................................................................13647
4. Radio, Rear left treble loudspeaker, Rear right treble loudspeaker, Rear left mid-range and bass loudspeaker, Rear right mid-range and bass loudspeaker........................................................................................................................................................................................................................................................................................................13648
5. Convenience system central control unit, Radio, Central locking and anti-theft alarm system aerial, TV tuner, Aerial amplifier 3...............................................................................................................................................................................................................................................................................................................................13649
6. Control unit 1 for information electronics, Radio, GPS aerial, Radio, telephone and navigation system aerial, Remote control receiver for auxiliary heater, Telephone aerial, TV tuner, Aerial amplifier 2, Satellite aerial, Auxiliary heater aerial, Digital radio aerial....................................................................................................................................................................................13650
147 -
Digital TV tuner...............................................................................................................................................................................................................................................................................................................................................................................................................................................13651
1.
Digital TV tuner..............................................................................................................................................................................................................................................................................................................................................................................................................................................13651
2. Reversing camera system control unit, Control unit 1 for information electronics, TV tuner.....................................................................................................................................................................................................................................................................................................................................................................13652
3. Convenience system central control unit, Radio, Central locking and anti-theft alarm system aerial, TV tuner, Aerial amplifier 3...............................................................................................................................................................................................................................................................................................................................13653
4. Control unit 1 for information electronics, Radio, GPS aerial, Radio, telephone and navigation system aerial, Remote control receiver for auxiliary heater, TV tuner, Aerial amplifier 2, Satellite aerial, Auxiliary heater aerial, Digital radio aerial......................................................................................................................................................................................................13654
148 -
MMI with radio and Standard sound system.......................................................................................................................................................................................................................................................................................................................................................................................................................13655
1.
MMI with radio and Standard sound system......................................................................................................................................................................................................................................................................................................................................................................................................................13655
2. Radio..........................................................................................................................................................................................................................................................................................................................................................................................................................................................13656
3. Radio, Front left treble loudspeaker, Front left mid-range and bass loudspeaker, Centre mid-range and treble loudspeaker.......................................................................................................................................................................................................................................................................................................................................13657
4. Radio, Front right treble loudspeaker, Front right mid-range and bass loudspeaker..............................................................................................................................................................................................................................................................................................................................................................................13658
5. Radio, Rear left treble loudspeaker, Rear right treble loudspeaker, Subwoofer in rear shelf, Rear left mid-range and bass loudspeaker, Rear right mid-range and bass loudspeaker...............................................................................................................................................................................................................................................................................13659
6. Radio, Central locking and anti-theft alarm system aerial, Aerial amplifier 3..................................................................................................................................................................................................................................................................................................................................................................................13660
7. Radio, GPS aerial, Radio, telephone and navigation system aerial, Telephone aerial, Aerial amplifier 2, Satellite aerial, Auxiliary heater aerial, Digital radio aerial........................................................................................................................................................................................................................................................................................13661
149 -
MMI with radio and Bang & Olufsen sound system.................................................................................................................................................................................................................................................................................................................................................................................................................13662
1.
MMI with radio and Bang & Olufsen sound system................................................................................................................................................................................................................................................................................................................................................................................................................13662
2. Radio..........................................................................................................................................................................................................................................................................................................................................................................................................................................................13663
3. Convenience system central control unit, Radio, Central locking and anti-theft alarm system aerial, TV tuner, Aerial amplifier 3...............................................................................................................................................................................................................................................................................................................................13664
4. Control unit 1 for information electronics, Radio, GPS aerial, Radio, telephone and navigation system aerial, Remote control receiver for auxiliary heater, Telephone aerial, TV tuner, Aerial amplifier 2, Satellite aerial, Auxiliary heater aerial..........................................................................................................................................................................................................13665
5. Digital sound package control unit, Internal microphone, Front left microphone, Front right microphone, Microphone unit in front roof module...................................................................................................................................................................................................................................................................................................................13666
6. Digital sound package control unit, Front left treble loudspeaker, Front left bass loudspeaker, Front left mid-range loudspeaker...............................................................................................................................................................................................................................................................................................................................13667
7. Digital sound package control unit, Front right treble loudspeaker, Front right bass loudspeaker, Front right mid-range loudspeaker, Centre mid-range and treble loudspeaker...................................................................................................................................................................................................................................................................................13668
8. Digital sound package control unit, Rear left treble loudspeaker, Rear right treble loudspeaker, Rear left mid-range and bass loudspeaker, Rear right mid-range and bass loudspeaker...........................................................................................................................................................................................................................................................................13669
9. Digital sound package control unit, Rear left mid-range loudspeaker, Rear right mid-range loudspeaker, Subwoofer in rear shelf.................................................................................................................................................................................................................................................................................................................................13670
150 -
4.2l petrol engine , CFSA......................................................................................................................................................................................................................................................................................................................................................................................................................................13671
1.
4.2l petrol engine , CFSA.....................................................................................................................................................................................................................................................................................................................................................................................................................................13671
2. Battery, Terminal 15 voltage supply relay......................................................................................................................................................................................................................................................................................................................................................................................................................13672
3. Battery isolation igniter, Terminal 30 wiring junction 2.......................................................................................................................................................................................................................................................................................................................................................................................................13673
4. Starter, Alternator, Voltage regulator, Terminal 30 wiring junction 2, Jump start socket.......................................................................................................................................................................................................................................................................................................................................................................13674
5. Main relay, Engine control unit, Engine component current supply relay.........................................................................................................................................................................................................................................................................................................................................................................................13675
6. Starter motor relay, Engine control unit, Starter motor relay 2................................................................................................................................................................................................................................................................................................................................................................................................13676
7. Map-controlled engine cooling system thermostat, Engine control unit, Activated charcoal filter solenoid valve 1, Left electrohydraulic engine mounting solenoid valve, Right electrohydraulic engine mounting solenoid valve, Valve for oil pressure control..................................................................................................................................................................................................13677
8. Secondary air pump relay, Secondary air pump 2 relay, Engine control unit, Secondary air inlet valve, Intake manifold flap valve, Coolant circulation pump, Secondary air pump motor, Secondary air pump motor 2...............................................................................................................................................................................................................................................13678
9. Engine control unit, Ignition coil 1 with output stage, Ignition coil 2 with output stage, Ignition coil 3 with output stage, Ignition coil 4 with output stage................................................................................................................................................................................................................................................................................................13679
10. Engine control unit, Ignition coil 5 with output stage, Ignition coil 6 with output stage, Ignition coil 7 with output stage, Ignition coil 8 with output stage...............................................................................................................................................................................................................................................................................................13680
11. Knock sensor 1, Knock sensor 2, Knock sensor 3, Throttle valve module, Engine control unit....................................................................................................................................................................................................................................................................................................................................................................13681
12. Hall sender, Knock sensor 4, Throttle valve module 2, Engine control unit.....................................................................................................................................................................................................................................................................................................................................................................................13682
13. Intake manifold flap potentiometer, Intake manifold flap potentiometer 2, Engine control unit.................................................................................................................................................................................................................................................................................................................................................................13683
14. Engine speed sender, Hall sender 3, Engine control unit.......................................................................................................................................................................................................................................................................................................................................................................................................13684
15. Intake air temperature sender, Fuel pressure sender, Engine control unit......................................................................................................................................................................................................................................................................................................................................................................................13685
16. Engine control unit, Camshaft control valve 1, Exhaust flap valve, Exhaust camshaft control valve 1...........................................................................................................................................................................................................................................................................................................................................................13686
17. Lambda probe, Lambda probe 2, Engine control unit.............................................................................................................................................................................................................................................................................................................................................................................................................13687
18. Lambda probe after catalytic converter, Lambda probe 2 after catalytic converter, Engine control unit.........................................................................................................................................................................................................................................................................................................................................................13688
19. Accelerator position sender, Engine control unit..............................................................................................................................................................................................................................................................................................................................................................................................................13689
20. Engine control unit, Injector, cylinder 1, Injector, cylinder 2, Injector, cylinder 6, Injector, cylinder 8...................................................................................................................................................................................................................................................................................................................................................13690
21. Engine control unit, Injector, cylinder 3, Injector, cylinder 4, Injector, cylinder 5, Injector, cylinder 7...................................................................................................................................................................................................................................................................................................................................................13691
22. Engine control unit, Fuel metering valve, Fuel metering valve 2...............................................................................................................................................................................................................................................................................................................................................................................................13692
23. Oil level and oil temperature sender, Engine control unit, Vacuum pump for brakes.............................................................................................................................................................................................................................................................................................................................................................................13693
24. Oil temperature sender, Engine control unit...................................................................................................................................................................................................................................................................................................................................................................................................................13694
25. Brake light switch, Oil pressure switch for reduced oil pressure, Engine control unit.........................................................................................................................................................................................................................................................................................................................................................................13695
26. Data bus diagnostic interface, Engine control unit, Mechatronic unit for dual clutch gearbox..................................................................................................................................................................................................................................................................................................................................................................13696
27. Control unit in dash panel insert, Data bus diagnostic interface..............................................................................................................................................................................................................................................................................................................................................................................................13697
28. Fuel delivery unit, Control unit in dash panel insert, Fuel pump control unit.................................................................................................................................................................................................................................................................................................................................................................................13698
29. Oil pressure switch, Coolant shortage indicator sender, Onboard supply control unit...........................................................................................................................................................................................................................................................................................................................................................................13699
151 -
2.0l diesel engine , CGLC,CGLD,CJCA,CJCB,CJCC,CJCD,CMFA,CMFB...................................................................................................................................................................................................................................................................................................................................................................................................13700
1.
2.0l diesel engine , CGLC,CGLD,CJCA,CJCB,CJCC,CJCD,CMFA,CMFB..................................................................................................................................................................................................................................................................................................................................................................................................13700
2. Battery, Terminal 15 voltage supply relay......................................................................................................................................................................................................................................................................................................................................................................................................................13701
3. Battery isolation igniter, Terminal 30 wiring junction 2.......................................................................................................................................................................................................................................................................................................................................................................................................13702
4. Starter, Alternator, Voltage regulator, Terminal 30 wiring junction 2, Jump start socket.......................................................................................................................................................................................................................................................................................................................................................................13703
5. Terminal 30 voltage supply relay, Engine control unit..........................................................................................................................................................................................................................................................................................................................................................................................................13704
6. Starter motor relay, Engine control unit, Starter motor relay 2................................................................................................................................................................................................................................................................................................................................................................................................13705
7. Automatic glow period control unit, Engine control unit........................................................................................................................................................................................................................................................................................................................................................................................................13706
8. Oil level and oil temperature sender, Engine control unit, Climatronic coolant shut-off valve, Coolant circulation pump, Pump for exhaust gas recirculation cooler.............................................................................................................................................................................................................................................................................................13707
9. Engine control unit, Charge pressure control solenoid valve, Heater element for crankcase breather, Left electrohydraulic engine mounting solenoid valve, Air filter bypass flap valve, Exhaust gas recirculation cooler changeover valve......................................................................................................................................................................................................................13708
10. Low heat output relay, High heat output relay, Engine control unit, Auxiliary air heater element..............................................................................................................................................................................................................................................................................................................................................................13709
11. Accelerator position sender, Accelerator position sender 2, Engine control unit...............................................................................................................................................................................................................................................................................................................................................................................13710
12. Engine speed sender, Hall sender, Fuel pressure sender, Brake servo pressure sensor, Engine control unit......................................................................................................................................................................................................................................................................................................................................................13711
13. Throttle valve potentiometer, Fuel temperature sender, Exhaust gas recirculation potentiometer, Position sender for charge pressure positioner, Throttle valve module, Engine control unit, Exhaust gas recirculation control motor...........................................................................................................................................................................................................................13712
14. Charge pressure sender, Intake air temperature sender, Pressure differential sender, Gearbox neutral position sender, Engine control unit.....................................................................................................................................................................................................................................................................................................................13713
15. Air mass meter, Engine control unit, Fuel pressure regulating valve, Fuel metering valve......................................................................................................................................................................................................................................................................................................................................................................13714
16. Coolant temperature sender, Radiator outlet coolant temperature sender, Exhaust gas temperature sender 1, Exhaust gas temperature sender 3, Exhaust gas temperature sender 4, Engine control unit.............................................................................................................................................................................................................................................................13715
17. Lambda probe, Engine control unit.............................................................................................................................................................................................................................................................................................................................................................................................................................13716
18. Engine control unit, Injector, cylinder 1, Injector, cylinder 2, Injector, cylinder 3, Injector, cylinder 4...................................................................................................................................................................................................................................................................................................................................................13717
19. NOx sender 2, Engine control unit, Control unit for NOx sender 2..............................................................................................................................................................................................................................................................................................................................................................................................13718
20. Engine control unit...........................................................................................................................................................................................................................................................................................................................................................................................................................................13719
21. Engine control unit, Control unit for reducing agent metering system, Relay for reducing agent metering system................................................................................................................................................................................................................................................................................................................................................13720
22. Tank sender for reducing agent, Temperature sender for reducing agent, Pressure sender for reducing agent metering system, Engine control unit, Control unit for reducing agent metering system, Heater for reducing-agent tank (heater circuit 1), Heate
for reducing-agent line (heater circuit 2).........................................................................................................................................................13721
23. Engine control unit, Control unit for reducing agent metering system, Transfer pump for reducing agent, Pump for reducing agent...............................................................................................................................................................................................................................................................................................................................13722
24. Clutch position sender, Engine control unit...................................................................................................................................................................................................................................................................................................................................................................................................................13723
25. Brake light switch, Oil pressure switch, Engine control unit..................................................................................................................................................................................................................................................................................................................................................................................................13724
26. Data bus diagnostic interface, Engine control unit............................................................................................................................................................................................................................................................................................................................................................................................................13725
27. Control unit in dash panel insert, Data bus diagnostic interface..............................................................................................................................................................................................................................................................................................................................................................................................13726
28. Fuel delivery unit, Fuel system pressurisation pump, Control unit in dash panel insert, Fuel pump control unit................................................................................................................................................................................................................................................................................................................................................13727
29. Coolant shortage indicator sender, Onboard supply control unit, Air conditioner compressor regulating valve...................................................................................................................................................................................................................................................................................................................................................13728
152 -
1.8l petrol engine , CDHA......................................................................................................................................................................................................................................................................................................................................................................................................................................13729
1.
1.8l petrol engine , CDHA.....................................................................................................................................................................................................................................................................................................................................................................................................................................13729
2. Battery, Terminal 15 voltage supply relay, Battery monitor control unit........................................................................................................................................................................................................................................................................................................................................................................................13730
3. Battery isolation igniter, Terminal 30 wiring junction 2.......................................................................................................................................................................................................................................................................................................................................................................................................13731
4. Starter, Alternator, Voltage regulator, Suppression filter, Terminal 30 wiring junction 2, Jump start socket...................................................................................................................................................................................................................................................................................................................................................13732
5. Main relay, Engine control unit, Engine component current supply relay.........................................................................................................................................................................................................................................................................................................................................................................................13733
6. Starter motor relay, Engine control unit, Starter motor relay 2................................................................................................................................................................................................................................................................................................................................................................................................13734
7. Oil level and oil temperature sender, Engine control unit......................................................................................................................................................................................................................................................................................................................................................................................................13735
8. Engine control unit, Charge pressure control solenoid valve, Activated charcoal filter solenoid valve 1, Left electrohydraulic engine mounting solenoid valve, Right electrohydraulic engine mounting solenoid valve, Camshaft control valve 1, Turbocharger air recirculation valve, Intake manifold flap valve...............................................................................................................................................13736
9. Engine control unit, Climatronic coolant shut-off valve, Valve for oil pressure control, Coolant circulation pump, Continued coolant circulation pump..........................................................................................................................................................................................................................................................................................................13737
10. Engine control unit, Engine component current supply relay 2, Ignition coil 1 with output stage, Ignition coil 2 with output stage, Ignition coil 3 with output stage, Ignition coil 4 with output stage......................................................................................................................................................................................................................................................13738
11. Accelerator position sender, Accelerator position sender 2, Engine control unit...............................................................................................................................................................................................................................................................................................................................................................................13739
12. Engine speed sender, Hall sender, Knock sensor 1, Engine control unit.........................................................................................................................................................................................................................................................................................................................................................................................13740
13. Charge pressure sender, Fuel pressure sender, Intake manifold flap potentiometer, Throttle valve module, Engine control unit..................................................................................................................................................................................................................................................................................................................................13741
14. Oil pressure switch, Oil pressure switch for reduced oil pressure, Intake air temperature sender, Coolant temperature sender, Engine control unit.............................................................................................................................................................................................................................................................................................................13742
15. Air mass meter, Brake servo pressure sensor, Gear detection sensor, Engine control unit, Fuel pressure regulating valve.......................................................................................................................................................................................................................................................................................................................................13743
16. Engine control unit, Injector, cylinder 1, Injector, cylinder 2, Injector, cylinder 3, Injector, cylinder 4...................................................................................................................................................................................................................................................................................................................................................13744
17. Lambda probe, Lambda probe after catalytic converter, Engine control unit.....................................................................................................................................................................................................................................................................................................................................................................................13745
18. Clutch position sender, Engine control unit...................................................................................................................................................................................................................................................................................................................................................................................................................13746
19. Brake light switch, Steering column electronics control unit, Engine control unit.............................................................................................................................................................................................................................................................................................................................................................................13747
20. Automatic gearbox control unit, Data bus diagnostic interface, Engine control unit............................................................................................................................................................................................................................................................................................................................................................................13748
21. Control unit in dash panel insert, Data bus diagnostic interface..............................................................................................................................................................................................................................................................................................................................................................................................13749
22. Control unit in dash panel insert, Fuel pump control unit.....................................................................................................................................................................................................................................................................................................................................................................................................13750
23. Coolant shortage indicator sender, Onboard supply control unit, Air conditioner compressor regulating valve...................................................................................................................................................................................................................................................................................................................................................13751
153 -
2.0l petrol engine , CNCD,CNCE,CUHA,CUJA.......................................................................................................................................................................................................................................................................................................................................................................................................................13752
1.
2.0l petrol engine , CNCD,CNCE,CUHA,CUJA......................................................................................................................................................................................................................................................................................................................................................................................................................13752
2. Battery, Terminal 15 voltage supply relay......................................................................................................................................................................................................................................................................................................................................................................................................................13753
3. Battery isolation igniter, Terminal 30 wiring junction 2.......................................................................................................................................................................................................................................................................................................................................................................................................13754
4. Starter, Alternator, Voltage regulator, Terminal 30 wiring junction 2, Jump start socket.......................................................................................................................................................................................................................................................................................................................................................................13755
5. Main relay, Engine component current supply relay..............................................................................................................................................................................................................................................................................................................................................................................................................13756
6. Starter motor relay, Starter motor relay 2.....................................................................................................................................................................................................................................................................................................................................................................................................................13757
7. Activated charcoal filter solenoid valve 1, Left electrohydraulic engine mounting solenoid valve, Right electrohydraulic engine mounting solenoid valve, Camshaft control valve 1, Turbocharger air recirculation valve, Exhaust camshaft control valve 1......................................................................................................................................................................................................13758
8. Actuator 1 for camshaft adjustment, Valve for oil pressure control, Piston cooling jet control valve...........................................................................................................................................................................................................................................................................................................................................................13759
9. Actuator 6 for camshaft adjustment, Actuator 7 for camshaft adjustment, Actuator 8 for camshaft adjustment.....................................................................................................................................................................................................................................................................................................................................................13760
10. Oil pressure switch, Oil pressure switch for reduced oil pressure, Coolant temperature sender, Radiator outlet coolant temperature sender.....................................................................................................................................................................................................................................................................................................................13761
11. Ignition coil 1 with output stage, Ignition coil 2 with output stage, Ignition coil 3 with output stage, Ignition coil 4 with output stage....................................................................................................................................................................................................................................................................................................................13762
12. Accelerator position sender, Accelerator position sender 2, Tank pressure sensor, Control unit for fuel tank leak detection...................................................................................................................................................................................................................................................................................................................................13763
13. Hall sender, Fuel pressure sender.............................................................................................................................................................................................................................................................................................................................................................................................................................13764
14. Engine speed sender, Throttle valve module....................................................................................................................................................................................................................................................................................................................................................................................................................13765
15. Hall sender 3, Intake manifold flap potentiometer, Fuel pressure sender for low-pressure......................................................................................................................................................................................................................................................................................................................................................................13766
16. Gear detection sensor, Injector, cylinder 1, Injector, cylinder 2, Injector, cylinder 3, Injector, cylinder 4.................................................................................................................................................................................................................................................................................................................................................13767
17. Injector 2, cylinder 1, Injector 2, cylinder 2, Injector 2, cylinder 3, Injector 2, cylinder 4................................................................................................................................................................................................................................................................................................................................................................13768
18. Lambda probe, Lambda probe after catalytic converter, Fuel metering valve.....................................................................................................................................................................................................................................................................................................................................................................................13769
19. Clutch pedal switch, Clutch pedal switch for engine start, Clutch position sender.............................................................................................................................................................................................................................................................................................................................................................................13770
20. Brake light switch, Steering column electronics control unit..................................................................................................................................................................................................................................................................................................................................................................................................13771
21. Data bus diagnostic interface.................................................................................................................................................................................................................................................................................................................................................................................................................................13772
22. Control unit in dash panel insert, Data bus diagnostic interface..............................................................................................................................................................................................................................................................................................................................................................................................13773
23. Fuel delivery unit, Control unit in dash panel insert, Fuel pump control unit.................................................................................................................................................................................................................................................................................................................................................................................13774
24. Coolant shortage indicator sender, Onboard supply control unit................................................................................................................................................................................................................................................................................................................................................................................................13775
154 -
2.0l diesel engine with start/stop system , CNHA,CNHC,CSUA,CSUB................................................................................................................................................................................................................................................................................................................................................................................................13776
1.
2.0l diesel engine with start/stop system , CNHA,CNHC,CSUA,CSUB...............................................................................................................................................................................................................................................................................................................................................................................................13776
2. Battery, Terminal 15 voltage supply relay......................................................................................................................................................................................................................................................................................................................................................................................................................13777
3. Battery isolation igniter, Terminal 30 wiring junction 2.......................................................................................................................................................................................................................................................................................................................................................................................................13778
4. Starter, Alternator, Voltage regulator, Terminal 30 wiring junction 2, Jump start socket.......................................................................................................................................................................................................................................................................................................................................................................13779
5. Terminal 30 voltage supply relay, Engine control unit..........................................................................................................................................................................................................................................................................................................................................................................................................13780
6. Starter motor relay, Engine control unit, Starter motor relay 2................................................................................................................................................................................................................................................................................................................................................................................................13781
7. Cylinder 3 combustion chamber pressure sender, Automatic glow period control unit, Engine control unit.........................................................................................................................................................................................................................................................................................................................................................13782
8. Oil level and oil temperature sender, Engine control unit, Valve for oil pressure control, Coolant valve for cylinder head, Charge air cooling pump, Auxiliary pump for heating................................................................................................................................................................................................................................................................................13783
9. Oil pressure switch, Oil pressure switch for reduced oil pressure, Engine control unit, Charge pressure control solenoid valve, Left electrohydraulic engine mounting solenoid valve, Air filter bypass flap valve.............................................................................................................................................................................................................................................13784
10. Low heat output relay, High heat output relay, Engine control unit, Auxiliary air heater element..............................................................................................................................................................................................................................................................................................................................................................13785
11. Accelerator position sender, Accelerator position sender 2, Engine control unit...............................................................................................................................................................................................................................................................................................................................................................................13786
12. Engine speed sender, Hall sender, Fuel pressure sender, Brake servo pressure sensor, Position sender for charge pressure positioner, Engine control unit......................................................................................................................................................................................................................................................................................................13787
13. Throttle valve potentiometer, Exhaust gas recirculation potentiometer, Exhaust gas recirculation potentiometer 2, Throttle valve module, Engine control unit, Exhaust gas recirculation control motor, Exhaust gas recirculation control motor 2..............................................................................................................................................................................................................13788
14. Charge pressure sender, Exhaust gas pressure sensor 1, Charge air temperature sender after charge air cooler, Engine control unit.............................................................................................................................................................................................................................................................................................................................13789
15. Coolant temperature sender, Fuel temperature sender, Pressure differential sender, Gearbox neutral position sender, Charge air temperature sender before charge air cooler, Engine control unit...............................................................................................................................................................................................................................................................13790
16. Air mass meter, Engine control unit, Heater element for crankcase breather, Camshaft control valve 1, Fuel pressure regulating valve, Fuel metering valve.....................................................................................................................................................................................................................................................................................................13791
17. Radiator outlet coolant temperature sender, Exhaust gas temperature sender 1, Exhaust gas temperature sender 2, Exhaust gas temperature sender 3, Exhaust gas temperature sender 4, Engine control unit.......................................................................................................................................................................................................................................................13792
18. Engine control unit, Injector, cylinder 1, Injector, cylinder 2, Injector, cylinder 3, Injector, cylinder 4...................................................................................................................................................................................................................................................................................................................................................13793
19. Lambda probe, Engine control unit, Exhaust flap control unit..................................................................................................................................................................................................................................................................................................................................................................................................13794
20. NOx sender, Control unit for NOx sender, Engine control unit, Injector for reducing agent.....................................................................................................................................................................................................................................................................................................................................................................13795
21. Engine control unit, Control unit for reducing agent metering system, Relay for reducing agent metering system................................................................................................................................................................................................................................................................................................................................................13796
22. Tank sender for reducing agent, Temperature sender for reducing agent, Pressure sender for reducing agent metering system, Engine control unit, Control unit for reducing agent metering system, Heater for reducing-agent tank (heater circuit 1), Heate
for reducing-agent line (heater circuit 2).........................................................................................................................................................13797
23. Engine control unit, Control unit for reducing agent metering system, Transfer pump for reducing agent, Pump for reducing agent...............................................................................................................................................................................................................................................................................................................................13798
24. Clutch position sender, Engine control unit...................................................................................................................................................................................................................................................................................................................................................................................................................13799
25. Brake light switch, Engine control unit.......................................................................................................................................................................................................................................................................................................................................................................................................................13800
26. Data bus diagnostic interface, Engine control unit............................................................................................................................................................................................................................................................................................................................................................................................................13801
27. Control unit in dash panel insert, Data bus diagnostic interface..............................................................................................................................................................................................................................................................................................................................................................................................13802
28. Fuel gauge sender, Fuel system pressurisation pump, Control unit in dash panel insert, Fuel pump control unit.................................................................................................................................................................................................................................................................................................................................................13803
155 -
3.0l diesel engine , CDUC,CKVB,CKVC,CKVD,CLAB..................................................................................................................................................................................................................................................................................................................................................................................................................13804
1.
3.0l diesel engine , CDUC,CKVB,CKVC,CKVD,CLAB.................................................................................................................................................................................................................................................................................................................................................................................................................13804
2. Battery, Terminal 15 voltage supply relay......................................................................................................................................................................................................................................................................................................................................................................................................................13805
3. Battery isolation igniter, Terminal 30 wiring junction 2.......................................................................................................................................................................................................................................................................................................................................................................................................13806
4. Starter, Alternator, Voltage regulator, Terminal 30 wiring junction 2, Jump start socket.......................................................................................................................................................................................................................................................................................................................................................................13807
5. Terminal 30 voltage supply relay, Engine control unit..........................................................................................................................................................................................................................................................................................................................................................................................................13808
6. Starter motor relay, Engine control unit, Starter motor relay 2................................................................................................................................................................................................................................................................................................................................................................................................13809
7. Cylinder 2 combustion chamber pressure sender, Automatic glow period control unit, Engine control unit.........................................................................................................................................................................................................................................................................................................................................................13810
8. Oil pressure switch for reduced oil pressure, Oil level and oil temperature sender, Engine control unit........................................................................................................................................................................................................................................................................................................................................................13811
9. Engine speed sender, Hall sender, Engine control unit..........................................................................................................................................................................................................................................................................................................................................................................................................13812
10. Engine control unit, Left electrohydraulic engine mounting solenoid valve, Right electrohydraulic engine mounting solenoid valve..............................................................................................................................................................................................................................................................................................................................13813
11. Low heat output relay, Engine control unit, Auxiliary air heater element......................................................................................................................................................................................................................................................................................................................................................................................13814
12. Accelerator position sender, Accelerator position sender 2, Engine control unit...............................................................................................................................................................................................................................................................................................................................................................................13815
13. Brake servo pressure sensor, Temperature sender for engine temperature regulation, Engine control unit........................................................................................................................................................................................................................................................................................................................................................13816
14. Throttle valve module, Engine control unit....................................................................................................................................................................................................................................................................................................................................................................................................................13817
15. Fuel pressure sender, Engine control unit, Turbocharger 1 control unit........................................................................................................................................................................................................................................................................................................................................................................................13818
16. Charge pressure sender, Intake air temperature sender, Air mass meter, Pressure differential sender, Engine control unit......................................................................................................................................................................................................................................................................................................................................13819
17. Control unit for NOx sender, Engine control unit..............................................................................................................................................................................................................................................................................................................................................................................................................13820
18. Engine control unit, Control unit for reducing agent metering system, Relay for reducing agent metering system................................................................................................................................................................................................................................................................................................................................................13821
19. Tank sender for reducing agent, Temperature sender for reducing agent, Pressure sender for reducing agent metering system, Engine control unit, Control unit for reducing agent metering system, Heater for reducing agent tank (heater circuit 1), Heate
for reducing agent line (heater circuit 2).........................................................................................................................................................13822
20. Engine control unit, Control unit for reducing agent metering system, Injector for reducing agent, Pump for reducing agent....................................................................................................................................................................................................................................................................................................................................13823
21. Coolant temperature sender, Fuel temperature sender, Radiator outlet coolant temperature sender, Engine control unit..........................................................................................................................................................................................................................................................................................................................................13824
22. Lambda probe, Engine control unit, Lambda probe heater........................................................................................................................................................................................................................................................................................................................................................................................................13825
23. Engine control unit, Injector, cylinder 1, Injector, cylinder 6...............................................................................................................................................................................................................................................................................................................................................................................................13826
24. Clutch position sender, Engine control unit...................................................................................................................................................................................................................................................................................................................................................................................................................13827
25. Brake light switch, Engine control unit.......................................................................................................................................................................................................................................................................................................................................................................................................................13828
26. Data bus diagnostic interface, Engine control unit............................................................................................................................................................................................................................................................................................................................................................................................................13829
27. Control unit in dash panel insert, Data bus diagnostic interface..............................................................................................................................................................................................................................................................................................................................................................................................13830
28. Fuel delivery unit, Control unit in dash panel insert, Fuel pump control unit.................................................................................................................................................................................................................................................................................................................................................................................13831
29. Coolant shortage indicator sender, Onboard supply control unit................................................................................................................................................................................................................................................................................................................................................................................................13832
156 -
Adjustable driver and front passenger seats....................................................................................................................................................................................................................................................................................................................................................................................................................13833
1.
Adjustable driver and front passenger seats...................................................................................................................................................................................................................................................................................................................................................................................................................13833
2. Driver seat adjustment thermal fuse 1..........................................................................................................................................................................................................................................................................................................................................................................................................................13834
3. Driver seat lumbar support longitudinal adjustment motor, Driver seat lumbar support height adjustment motor...................................................................................................................................................................................................................................................................................................................................................13835
4. Driver seat longitudinal adjustment motor, Driver seat backrest adjustment motor, Driver seat rake adjustment motor, Driver seat height adjustment motor.......................................................................................................................................................................................................................................................................................................13836
5. Front passenger seat adjustment thermal fuse 1, Rear right footwell light......................................................................................................................................................................................................................................................................................................................................................................................13837
6. Front passenger seat lumbar support longitudinal adjustment motor, Front passenger seat lumbar support height adjustment motor.................................................................................................................................................................................................................................................................................................................................13838
7. Front passenger seat longitudinal adjustment motor, Front passenger seat backrest adjustment motor, Front passenger seat rake adjustment motor, Front passenger seat height adjustment motor...................................................................................................................................................................................................................................................................13839
157 -
3.0l petrol engine , CREC,CRED,CTDA............................................................................................................................................................................................................................................................................................................................................................................................................................13840
1.
3.0l petrol engine , CREC,CRED,CTDA...........................................................................................................................................................................................................................................................................................................................................................................................................................13840
2. Battery, Terminal 15 voltage supply relay......................................................................................................................................................................................................................................................................................................................................................................................................................13841
3. Battery isolation igniter, Terminal 30 wiring junction 2.......................................................................................................................................................................................................................................................................................................................................................................................................13842
4. Starter, Alternator, Voltage regulator, Terminal 30 wiring junction 2, Jump start socket.......................................................................................................................................................................................................................................................................................................................................................................13843
5. Main relay, Engine component current supply relay..............................................................................................................................................................................................................................................................................................................................................................................................................13844
6. Starter motor relay, Starter motor relay 2.....................................................................................................................................................................................................................................................................................................................................................................................................................13845
7. Camshaft control valve 1, Camshaft control valve 2, Intake manifold flap valve, Exhaust camshaft control valve 1, Exhaust camshaft control valve 2, Coolant circulation pump...................................................................................................................................................................................................................................................................................13846
8. Brake servo pressure sensor, Gear detection sensor, Left electrohydraulic engine mounting solenoid valve, Right electrohydraulic engine mounting solenoid valve, Magnetic clutch for supercharger, Charge air cooling pump.....................................................................................................................................................................................................................................13847
9. Activated charcoal filter solenoid valve 1, Secondary air inlet valve, Valve for oil pressure control, Actuator for engine temperature regulation, Crankcase breather shut-off valve, Engine oil cooler valve..................................................................................................................................................................................................................................................13848
10. Secondary air pump relay, Ignition coil 1 with output stage, Ignition coil 2 with output stage, Ignition coil 3 with output stage, Secondary air pump motor...................................................................................................................................................................................................................................................................................................13849
11. Ignition coil 4 with output stage, Ignition coil 5 with output stage, Ignition coil 6 with output stage.......................................................................................................................................................................................................................................................................................................................................................13850
12. Oil pressure switch, Oil pressure switch for reduced oil pressure, Knock sensor 1, Knock sensor 2, Accelerator position sender, Accelerator position sender 2.................................................................................................................................................................................................................................................................................................13851
13. Intake air temperature sender, Coolant temperature sender, Intake manifold pressure sender, Fuel pressure sender, Fuel pressure sender for low-pressure, Sender 1 for turbocharger speed, Throttle valve module...............................................................................................................................................................................................................................................13852
14. Hall sender, Hall sender 2, Hall sender 3, Intake manifold flap potentiometer, Intake manifold flap potentiometer 2...........................................................................................................................................................................................................................................................................................................................................13853
15. Engine speed sender, Charge pressure sender, Intake manifold temperature sender, Hall sender 4, Regulating flap control unit..................................................................................................................................................................................................................................................................................................................................13854
16. Tank pressure sensor, Intake manifold temperature sender 2, Charge pressure sender 2, Temperature sender for engine temperature regulation, Control unit for fuel tank leak detection, Fuel metering valve....................................................................................................................................................................................................................................................13855
17. Injector, cylinder 1, Injector, cylinder 2, Injector, cylinder 3, Injector, cylinder 4, Injector, cylinder 5, Injector, cylinder 6............................................................................................................................................................................................................................................................................................................................13856
18. Injector 2, cylinder 1, Injector 2, cylinder 2, Injector 2, cylinder 3, Injector 2, cylinder 4, Injector 2, cylinder 5, Injector 2, cylinder 6................................................................................................................................................................................................................................................................................................................13857
19. Lambda probe, Lambda probe 2..................................................................................................................................................................................................................................................................................................................................................................................................................................13858
20. Lambda probe after catalytic converter, Lambda probe 2 after catalytic converter..............................................................................................................................................................................................................................................................................................................................................................................13859
21. Clutch position sender........................................................................................................................................................................................................................................................................................................................................................................................................................................13860
22. Brake light switch, Oil level and oil temperature sender, Steering column electronics control unit............................................................................................................................................................................................................................................................................................................................................................13861
23. Data bus diagnostic interface.................................................................................................................................................................................................................................................................................................................................................................................................................................13862
24. Control unit in dash panel insert, Data bus diagnostic interface..............................................................................................................................................................................................................................................................................................................................................................................................13863
25. Fuel delivery unit, Control unit in dash panel insert, Fuel pump control unit.................................................................................................................................................................................................................................................................................................................................................................................13864
26. Coolant shortage indicator sender, Onboard supply control unit................................................................................................................................................................................................................................................................................................................................................................................................13865
801 - - Fitting locations: Earth points - 3...........................................................................................................................................................................................................................................................................................................................................................................................................................13866
1. Earth points...................................................................................................................................................................................................................................................................................................................................................................................................................................................13866
1.1 Overview of earth points - coupe models (2-door)..........................................................................................................................................................................................................................................................................................................................................................................................................13867
1.2 Overview of earth points - sportback models (5-door)......................................................................................................................................................................................................................................................................................................................................................................................................13870
802 - -Fitting locations: fuses - 3...................................................................................................................................................................................................................................................................................................................................................................................................................................13880
1. Fuses..........................................................................................................................................................................................................................................................................................................................................................................................................................................................13880
1.1 Overview of fuses.........................................................................................................................................................................................................................................................................................................................................................................................................................................13880
1.2 Fuse holder A -SA-........................................................................................................................................................................................................................................................................................................................................................................................................................................13883
1.2.1 Fuses on fuse holder A -SA-.........................................................................................................................................................................................................................................................................................................................................................................................................................13883
1.3 Relay/fuse holder B -SB- up to July 2011..................................................................................................................................................................................................................................................................................................................................................................................................................13884
1.3.1 Fuses in fuse carrier ST1 on fuse holder B -SB- (black).............................................................................................................................................................................................................................................................................................................................................................................................13887
1.4 Relay/fuse holder B -SB- from August 2011.................................................................................................................................................................................................................................................................................................................................................................................................................13891
1.4.1 Fuses in fuse carrier ST1 on fuse holder B -SB- (black).............................................................................................................................................................................................................................................................................................................................................................................................13894
1.5 Fuse holder C -SC- up to model year 2009..................................................................................................................................................................................................................................................................................................................................................................................................................13897
1.5.1 Fuses in fuse carrier ST1 on fuse holder C -SC- (black).............................................................................................................................................................................................................................................................................................................................................................................................13900
1.5.2 Fuses in fuse carrier ST2 on fuse holder C -SC- (brown).............................................................................................................................................................................................................................................................................................................................................................................................13901
1.5.3 Fuses in fuse carrier ST3 on fuse holder C -SC- (red)...............................................................................................................................................................................................................................................................................................................................................................................................13901
1.6 Fuse holder C -SC- from model year 2010...................................................................................................................................................................................................................................................................................................................................................................................................................13902
1.6.1 Fuses in fuse carrier ST1 on fuse holder C -SC- (black).............................................................................................................................................................................................................................................................................................................................................................................................13905
1.6.2 Fuses in fuse carrier ST2 on fuse holder C -SC- (brown).............................................................................................................................................................................................................................................................................................................................................................................................13906
1.6.3 Fuses in fuse carrier ST3, fuse holder C -SC- (red).................................................................................................................................................................................................................................................................................................................................................................................................13907
1.7 Fuse holder C -SC- from August 2011.......................................................................................................................................................................................................................................................................................................................................................................................................................13907
1.7.1 Fuses in fuse carrier ST1 on fuse holder C -SC- (black).............................................................................................................................................................................................................................................................................................................................................................................................13910
1.7.2 Fuses in fuse carrier ST2 on fuse holder C -SC- (brown).............................................................................................................................................................................................................................................................................................................................................................................................13911
1.7.3 Fuses in fuse carrier ST3, fuse holder C -SC- (red).................................................................................................................................................................................................................................................................................................................................................................................................13912
1.8 Fuse holder D -SD-........................................................................................................................................................................................................................................................................................................................................................................................................................................13912
1.8.1 Fuses in fuse carrier ST1 on fuse holder D -SD- (black).............................................................................................................................................................................................................................................................................................................................................................................................13915
1.8.2 Fuses in fuse carrier ST2 on fuse holder D -SD- (brown).............................................................................................................................................................................................................................................................................................................................................................................................13916
1.9 Relay/fuse holder F -SF- up to model year 2009............................................................................................................................................................................................................................................................................................................................................................................................................13916
1.9.1 Fuses in fuse carrier ST1 on fuse holder F -SF- (black).............................................................................................................................................................................................................................................................................................................................................................................................13917
1.9.2 Fuses in fuse carrier ST2 on fuse holder F -SF- (black).............................................................................................................................................................................................................................................................................................................................................................................................13918
1.9.3 Fuses in fuse carrier ST3 on fuse holder F -SF- (brown).............................................................................................................................................................................................................................................................................................................................................................................................13919
1.9.4 Fuses in fuse carrier ST4 on fuse holder F -SF- (red)...............................................................................................................................................................................................................................................................................................................................................................................................13919
1.9.5 Fuses in fuse carrier ST5 on fuse holder F -SF- (black).............................................................................................................................................................................................................................................................................................................................................................................................13920
1.9.6 Separate fuses on fuse holder F -SF-................................................................................................................................................................................................................................................................................................................................................................................................................13920
1.10 Relay/fuse holder F -SF- from model year 2010............................................................................................................................................................................................................................................................................................................................................................................................................13921
1.10.1 Fuses in fuse carrier ST1 on fuse holder F -SF- (black)............................................................................................................................................................................................................................................................................................................................................................................................13922
1.10.2 Fuses in fuse carrier ST2 on fuse holder F -SF- (black)............................................................................................................................................................................................................................................................................................................................................................................................13922
1.10.3 Fuses in fuse carrier ST3 on fuse holder F -SF- (brown)............................................................................................................................................................................................................................................................................................................................................................................................13923
1.10.4 Fuses in fuse carrier ST4 on fuse holder F -SF- (red)..............................................................................................................................................................................................................................................................................................................................................................................................13924
1.10.5 Fuses in fuse carrier ST5 on fuse holder F -SF- (black)............................................................................................................................................................................................................................................................................................................................................................................................13924
1.10.6 Separate fuses on fuse holder F -SF-...............................................................................................................................................................................................................................................................................................................................................................................................................13925
1.11 Relay/fuse holder F -SF- from August 2011................................................................................................................................................................................................................................................................................................................................................................................................................13925
1.11.1 Fuses in fuse carrier ST1 on fuse holder F -SF- (black)............................................................................................................................................................................................................................................................................................................................................................................................13926
1.11.2 Fuses in fuse carrier ST2 on fuse holder F -SF- (black)............................................................................................................................................................................................................................................................................................................................................................................................13927
1.11.3 Fuses in fuse carrier ST3 on fuse holder F -SF- (brown)............................................................................................................................................................................................................................................................................................................................................................................................13928
1.11.4 Fuses in fuse carrier ST4 on fuse holder F -SF- (red)..............................................................................................................................................................................................................................................................................................................................................................................................13928
1.11.5 Fuses in fuse carrier ST5 on fuse holder F -SF- (black)............................................................................................................................................................................................................................................................................................................................................................................................13929
1.11.6 Separate fuses on fuse holder F -SF-...............................................................................................................................................................................................................................................................................................................................................................................................................13930
1.12 Terminal 30 wiring junction 2 -TV22- with jump start socket -U6- up to July 2011.........................................................................................................................................................................................................................................................................................................................................................................13930
1.12.1 Fuses on Terminal 30 wiring junction 2 -TV22- with jump start socket -U6-..........................................................................................................................................................................................................................................................................................................................................................................13931
1.13 Terminal 30 wiring junction 2 -TV22- with jump start socket -U6- from August 2011........................................................................................................................................................................................................................................................................................................................................................................13932
1.13.1 Fuses on Terminal 30 wiring junction 2 -TV22- with jump start socket -U6-..........................................................................................................................................................................................................................................................................................................................................................................13933
1.14 3-pin relay and fuse holder..............................................................................................................................................................................................................................................................................................................................................................................................................................13933
1.15 6-pin coupling station of A-pillar, driver side..........................................................................................................................................................................................................................................................................................................................................................................................................13936
1.16 6-pin coupling station of A-pillar, front passenger side.................................................................................................................................................................................................................................................................................................................................................................................................13939
1.17 Relay/fuse holder with onboard control unit -J519-.......................................................................................................................................................................................................................................................................................................................................................................................................13942
803 - -Fitting locations: Relays - 3..................................................................................................................................................................................................................................................................................................................................................................................................................................13945
1. Relays.........................................................................................................................................................................................................................................................................................................................................................................................................................................................13945
1.1 Overview of relays........................................................................................................................................................................................................................................................................................................................................................................................................................................13945
1.2 Relay/fuse holder with onboard control unit -J519-........................................................................................................................................................................................................................................................................................................................................................................................................13947
1.3 3-pin relay and fuse holder...............................................................................................................................................................................................................................................................................................................................................................................................................................13950
1.4 Relay/fuse holder B -SB-..................................................................................................................................................................................................................................................................................................................................................................................................................................13953
1.5 Relay/fuse holder F -SF- up to July 2011..................................................................................................................................................................................................................................................................................................................................................................................................................13956
1.6 Relay/fuse holder F -SF- from August 2011.................................................................................................................................................................................................................................................................................................................................................................................................................13956
804 - -Fitting locations: control units in front part of vehicle - 3.................................................................................................................................................................................................................................................................................................................................................................................................13958
1. Control units in front part of vehicle.........................................................................................................................................................................................................................................................................................................................................................................................................................13958
1.1 Overview of control units.................................................................................................................................................................................................................................................................................................................................................................................................................................13959
1.2 Engine control unit -J623-................................................................................................................................................................................................................................................................................................................................................................................................................................13960
1.3 Left gas discharge light control unit -J343-, up to model year 2012.......................................................................................................................................................................................................................................................................................................................................................................................13966
1.4 Right gas discharge light control unit -J344-, up to model year 2012......................................................................................................................................................................................................................................................................................................................................................................................13967
1.5 Left gas discharge light control unit -J343-, from model year 2013........................................................................................................................................................................................................................................................................................................................................................................................13968
1.6 Right gas discharge light control unit -J344-, from model year 2013.......................................................................................................................................................................................................................................................................................................................................................................................13969
1.7 Auxiliary heater control unit -J364-......................................................................................................................................................................................................................................................................................................................................................................................................................13970
1.8 Automatic gearbox control unit -J217- / Mechatronics for dual clutch gearbox -J743-...............................................................................................................................................................................................................................................................................................................................................................13971
1.9 Wiper motor control unit -J400-...........................................................................................................................................................................................................................................................................................................................................................................................................................13972
1.10 ABS control unit -J104-..................................................................................................................................................................................................................................................................................................................................................................................................................................13973
1.11 400 W or 600 W radiator fan..............................................................................................................................................................................................................................................................................................................................................................................................................................13974
1.12 800 W or 1000 W radiator fan.............................................................................................................................................................................................................................................................................................................................................................................................................................13976
1.13 Garage door operation control unit -J530-................................................................................................................................................................................................................................................................................................................................................................................................................13977
1.14 Adaptive cruise control unit -J428-...................................................................................................................................................................................................................................................................................................................................................................................................................13978
805 - -Fitting locations: Control units in interior and rear part of vehicle - 3......................................................................................................................................................................................................................................................................................................................................................................................13979
1. Control units in interior and rear part of vehicle.............................................................................................................................................................................................................................................................................................................................................................................................................13979
1.1 Overview of control units in interior of vehicle - coupe models (2-door)..................................................................................................................................................................................................................................................................................................................................................................................13979
1.2 Overview of control units in interior of vehicle - sportback models (5-door)..............................................................................................................................................................................................................................................................................................................................................................................13983
1.3 Overview of control units in rear part of vehicle - coupe models (2-door) only............................................................................................................................................................................................................................................................................................................................................................................13986
1.4 Overview of control units in rear part of vehicle - sportback models (5-door) only........................................................................................................................................................................................................................................................................................................................................................................13989
1.5 Control unit for headlight range control -J431- / control unit for cornering light and headlight range control -J745-.....................................................................................................................................................................................................................................................................................................................................13991
1.6 Fresh air blower control unit -J126-......................................................................................................................................................................................................................................................................................................................................................................................................................13992
1.7 Driver door control unit -J386-...........................................................................................................................................................................................................................................................................................................................................................................................................................13993
1.8 Front passenger door control unit -J387-..................................................................................................................................................................................................................................................................................................................................................................................................................13993
1.8.1 Connectors on driver door control unit -J386-.......................................................................................................................................................................................................................................................................................................................................................................................................13993
1.8.2 Connectors on front passenger door control unit -J387-..............................................................................................................................................................................................................................................................................................................................................................................................13995
1.9 Automatic anti-dazzle interior mirror -Y7- with rain and light sensor -G397-..............................................................................................................................................................................................................................................................................................................................................................................13996
1.10 Sliding sunroof adjustment control unit -J245- with sliding sunroof motor -V1-...........................................................................................................................................................................................................................................................................................................................................................................13997
1.11 Onboard supply control unit -J519-.......................................................................................................................................................................................................................................................................................................................................................................................................................13998
1.12 Active steering control unit -J792-......................................................................................................................................................................................................................................................................................................................................................................................................................14001
1.13 Radio -R- (with integrated CD changer -R41- / DVD changer -R161-)........................................................................................................................................................................................................................................................................................................................................................................................14002
1.14 CD changer -R41- / DVD changer -R161-....................................................................................................................................................................................................................................................................................................................................................................................................................14003
1.15 Chip card reader control unit -J676-.....................................................................................................................................................................................................................................................................................................................................................................................................................14004
1.16 Display unit for front information display and operating unit control unit -J685-........................................................................................................................................................................................................................................................................................................................................................................14005
1.17 Control unit for information electronics 1 -J794-........................................................................................................................................................................................................................................................................................................................................................................................................14007
1.18 Multimedia system operating unit -E380-..................................................................................................................................................................................................................................................................................................................................................................................................................14008
1.19 Climatronic control unit -J255-..........................................................................................................................................................................................................................................................................................................................................................................................................................14009
1.20 Airbag control unit -J234-...............................................................................................................................................................................................................................................................................................................................................................................................................................14010
1.21 Telephone transmitter and receiver unit -R36-............................................................................................................................................................................................................................................................................................................................................................................................................14011
1.22 16-pin connector -T16-, diagnosis connection.............................................................................................................................................................................................................................................................................................................................................................................................................14012
1.23 Data bus diagnostic interface -J533-.....................................................................................................................................................................................................................................................................................................................................................................................................................14013
1.24 Control unit in dash panel insert -J285-.................................................................................................................................................................................................................................................................................................................................................................................................................14014
1.25 Control units on right in luggage compartment............................................................................................................................................................................................................................................................................................................................................................................................................14015
1.25.1 Connectors on convenience system central control unit -J393-.......................................................................................................................................................................................................................................................................................................................................................................................14015
1.25.2 Connectors on electronically controlled damping control unit -J250-................................................................................................................................................................................................................................................................................................................................................................................14017
1.25.3 Connectors on trailer detector control unit -J345-.................................................................................................................................................................................................................................................................................................................................................................................................14018
1.25.4 Connectors on park assist steering control unit -J791-.............................................................................................................................................................................................................................................................................................................................................................................................14019
1.26 All-wheel drive control unit -J492-......................................................................................................................................................................................................................................................................................................................................................................................................................14019
1.27 Voltage stabiliser -J532-................................................................................................................................................................................................................................................................................................................................................................................................................................14022
1.28 Battery monitor control unit -J367-......................................................................................................................................................................................................................................................................................................................................................................................................................14023
806 - - Fitting locations: Coupling stations - 3......................................................................................................................................................................................................................................................................................................................................................................................................................14024
1. Coupling stations..............................................................................................................................................................................................................................................................................................................................................................................................................................................14024
1.1 Overview of coupling stations.............................................................................................................................................................................................................................................................................................................................................................................................................................14024
1.2 6-pin coupling station of A-pillar, front passenger side..................................................................................................................................................................................................................................................................................................................................................................................................14026
1.3 Fuse holder D -SD-........................................................................................................................................................................................................................................................................................................................................................................................................................................14029
1.4 Seat wiring coupling station, driver side.................................................................................................................................................................................................................................................................................................................................................................................................................14032
1.5 Seat wiring coupling station, front passenger side........................................................................................................................................................................................................................................................................................................................................................................................................14032
1.6 6-pin coupling station of A-pillar, driver side...........................................................................................................................................................................................................................................................................................................................................................................................................14033
1.7 Relay/fuse holder B -SB-..................................................................................................................................................................................................................................................................................................................................................................................................................................14036
1.8 Relay/fuse holder with onboard control unit -J519-........................................................................................................................................................................................................................................................................................................................................................................................................14038
1.9 Connection for external audio sources -R199- as Audi music interface (AMI - MOST).........................................................................................................................................................................................................................................................................................................................................................................14041
1.10 Connection for external audio sources -R199- as Audi music interface (AMI - CAN).........................................................................................................................................................................................................................................................................................................................................................................14042
1.11 Connection for external audio sources -R199- as AUX connection...........................................................................................................................................................................................................................................................................................................................................................................................14044
Servicing_6-speed_manual_gearbox_0B1__front-wheel_drive...................................................................................................................................................................................................................................................................................................................................................................................................................14046
00 – Technical data...................................................................................................................................................................................................................................................................................................................................................................................................................................................14050
1 Identification..................................................................................................................................................................................................................................................................................................................................................................................................................................................14050
1.1 Gearbox identification....................................................................................................................................................................................................................................................................................................................................................................................................................................14050
2 Repair instructions.............................................................................................................................................................................................................................................................................................................................................................................................................................................14051
2.1 General repair instructions...............................................................................................................................................................................................................................................................................................................................................................................................................................14051
30 – Clutch...........................................................................................................................................................................................................................................................................................................................................................................................................................................................14057
1 Clutch mechanism................................................................................................................................................................................................................................................................................................................................................................................................................................................14057
1.1 Exploded view - clutch release mechanism..................................................................................................................................................................................................................................................................................................................................................................................................................14057
1.2 Servicing clutch release mechanism........................................................................................................................................................................................................................................................................................................................................................................................................................14060
2 Clutch..........................................................................................................................................................................................................................................................................................................................................................................................................................................................14061
2.1 General notes on clutch...................................................................................................................................................................................................................................................................................................................................................................................................................................14061
2.2 Exploded view - clutch unit...............................................................................................................................................................................................................................................................................................................................................................................................................................14065
2.2.1 Exploded view - Sachs version clutch................................................................................................................................................................................................................................................................................................................................................................................................................14065
2.2.2 Exploded view - SAC clutch, LuK version.............................................................................................................................................................................................................................................................................................................................................................................................................14070
2.3 Removing and installing clutch module.....................................................................................................................................................................................................................................................................................................................................................................................................................14074
2.4 Removing and installing clutch............................................................................................................................................................................................................................................................................................................................................................................................................................14078
2.4.1 Removing and installing Sachs version clutch........................................................................................................................................................................................................................................................................................................................................................................................................14078
2.4.2 Removing and installing LuK version clutch..........................................................................................................................................................................................................................................................................................................................................................................................................14082
2.5 Resetting adjuster ring in pressure plate, LuK version....................................................................................................................................................................................................................................................................................................................................................................................................14085
2.6 Renewing needle bearing/ball bearing for dual-mass flywheel...............................................................................................................................................................................................................................................................................................................................................................................................14087
34 – Controls, housing................................................................................................................................................................................................................................................................................................................................................................................................................................................14091
1 Transporting gearbox............................................................................................................................................................................................................................................................................................................................................................................................................................................14091
2 Dismantling and assembling gearbox..............................................................................................................................................................................................................................................................................................................................................................................................................................14092
2.1 Schematic overview - gearbox..............................................................................................................................................................................................................................................................................................................................................................................................................................14092
2.2 Exploded view - gearbox...................................................................................................................................................................................................................................................................................................................................................................................................................................14093
2.3 Exploded view - gear cluster, reverse gear wheel, selector mechanism......................................................................................................................................................................................................................................................................................................................................................................................14097
2.4 Exploded view - selector forks............................................................................................................................................................................................................................................................................................................................................................................................................................14099
2.5 Dismantling and assembling gearbox........................................................................................................................................................................................................................................................................................................................................................................................................................14101
2.6 Removing and installing selector shaft....................................................................................................................................................................................................................................................................................................................................................................................................................14117
3 Gearbox housing, clutch housing.................................................................................................................................................................................................................................................................................................................................................................................................................................14120
3.1 Exploded view - end cover.................................................................................................................................................................................................................................................................................................................................................................................................................................14120
3.2 Exploded view - gearbox cover.............................................................................................................................................................................................................................................................................................................................................................................................................................14121
3.3 Exploded view - gearbox housing...........................................................................................................................................................................................................................................................................................................................................................................................................................14123
3.4 Servicing end cover.......................................................................................................................................................................................................................................................................................................................................................................................................................................14125
3.5 Servicing gearbox cover...................................................................................................................................................................................................................................................................................................................................................................................................................................14126
3.6 Servicing gearbox housing.................................................................................................................................................................................................................................................................................................................................................................................................................................14136
4 Securing to engine and gearbox support..........................................................................................................................................................................................................................................................................................................................................................................................................................14140
35 – Gears, shafts....................................................................................................................................................................................................................................................................................................................................................................................................................................................14142
1 Dismantling and assembling gears and shafts.....................................................................................................................................................................................................................................................................................................................................................................................................................14142
1.1 Exploded view - gear cluster..............................................................................................................................................................................................................................................................................................................................................................................................................................14142
1.2 Dismantling and assembling gear cluster...................................................................................................................................................................................................................................................................................................................................................................................................................14144
2 Input shaft.....................................................................................................................................................................................................................................................................................................................................................................................................................................................14152
2.1 Exploded view - input shaft...............................................................................................................................................................................................................................................................................................................................................................................................................................14152
2.2 Dismantling and assembling input shaft....................................................................................................................................................................................................................................................................................................................................................................................................................14156
2.3 Allocation of 3rd - 6th gear synchro-rings to locking collars.............................................................................................................................................................................................................................................................................................................................................................................................14165
2.4 Checking 3rd - 6th gear synchro-rings for wear............................................................................................................................................................................................................................................................................................................................................................................................................14166
3 Output shaft....................................................................................................................................................................................................................................................................................................................................................................................................................................................14167
3.1 Exploded view - output shaft..............................................................................................................................................................................................................................................................................................................................................................................................................................14167
3.2 Dismantling and assembling output shaft...................................................................................................................................................................................................................................................................................................................................................................................................................14171
39 – Final drive - differential.......................................................................................................................................................................................................................................................................................................................................................................................................................................14176
1 Final drive.....................................................................................................................................................................................................................................................................................................................................................................................................................................................14176
1.1 Exploded view - final drive...............................................................................................................................................................................................................................................................................................................................................................................................................................14176
2 Oil seals.......................................................................................................................................................................................................................................................................................................................................................................................................................................................14178
2.1 Overview of fitting locations - oil seals.................................................................................................................................................................................................................................................................................................................................................................................................................14178
2.2 Renewing oil seal (right-side)............................................................................................................................................................................................................................................................................................................................................................................................................................14179
2.3 Renewing oil seal (left-side).............................................................................................................................................................................................................................................................................................................................................................................................................................14180
2.4 Renewing input shaft oil seal.............................................................................................................................................................................................................................................................................................................................................................................................................................14184
3 Differential....................................................................................................................................................................................................................................................................................................................................................................................................................................................14187
3.1 Exploded view - differential..............................................................................................................................................................................................................................................................................................................................................................................................................................14187
3.2 Removing and installing flange shaft (right-side).........................................................................................................................................................................................................................................................................................................................................................................................................14189
3.3 Removing and installing flange shaft (left-side)..........................................................................................................................................................................................................................................................................................................................................................................................................14191
3.4 Checking and adjusting preload of ball bearing for flange shaft (left-side)...............................................................................................................................................................................................................................................................................................................................................................................14195
3.4.1 Checking preload of ball bearing for flange shaft (left-side) - vehicles with vehicle ID No. up to 8K0BA088680 or 8FXBN009589.......................................................................................................................................................................................................................................................................................................................14195
3.4.2 Optimising preload of ball bearing for flange shaft (left-side) - vehicles with vehicle ID No. up to 8K0BA088680 or 8FXBN009589.....................................................................................................................................................................................................................................................................................................................14196
3.4.3 Adjusting preload of ball bearing for flange shaft (left-side) - vehicles with vehicle ID No. up to 8K0BA088680 or 8FXBN009589......................................................................................................................................................................................................................................................................................................................14197
3.5 Renewing mounting bracket and ball bearing for flange shaft (left-side)...................................................................................................................................................................................................................................................................................................................................................................................14200
3.6 Removing and installing differential......................................................................................................................................................................................................................................................................................................................................................................................................................14202
3.7 Renewing cover for final drive............................................................................................................................................................................................................................................................................................................................................................................................................................14204
3.7.1 Renewing cover for final drive, version with tapered roller bearings up to gearbox manufacturing date 14 08 11......................................................................................................................................................................................................................................................................................................................................14204
3.7.2 Renewing cover for final drive, version with angular contact ball bearing (high-efficiency bearing) from gearbox manufacturing date 15 08 11 onwards................................................................................................................................................................................................................................................................................................14211
3.8 Dismantling and assembling differential...................................................................................................................................................................................................................................................................................................................................................................................................................14216
3.9 Adjusting differential....................................................................................................................................................................................................................................................................................................................................................................................................................................14224
Servicing_6-speed_manual_gearbox_0B2__four-wheel_drive....................................................................................................................................................................................................................................................................................................................................................................................................................14233
00 – Technical data...................................................................................................................................................................................................................................................................................................................................................................................................................................................14237
1 Identification..................................................................................................................................................................................................................................................................................................................................................................................................................................................14237
1.1 Gearbox identification....................................................................................................................................................................................................................................................................................................................................................................................................................................14237
2 Repair instructions.............................................................................................................................................................................................................................................................................................................................................................................................................................................14238
2.1 General repair instructions...............................................................................................................................................................................................................................................................................................................................................................................................................................14238
30 – Clutch...........................................................................................................................................................................................................................................................................................................................................................................................................................................................14244
1 Clutch mechanism................................................................................................................................................................................................................................................................................................................................................................................................................................................14244
1.1 Exploded view - clutch release mechanism..................................................................................................................................................................................................................................................................................................................................................................................................................14244
1.2 Servicing clutch release mechanism........................................................................................................................................................................................................................................................................................................................................................................................................................14247
2 Clutch..........................................................................................................................................................................................................................................................................................................................................................................................................................................................14248
2.1 General notes on clutch...................................................................................................................................................................................................................................................................................................................................................................................................................................14248
2.2 Exploded view - clutch unit...............................................................................................................................................................................................................................................................................................................................................................................................................................14252
2.2.1 Exploded view - Sachs version clutch................................................................................................................................................................................................................................................................................................................................................................................................................14252
2.2.2 Exploded view - LuK version clutch..................................................................................................................................................................................................................................................................................................................................................................................................................14257
2.3 Removing and installing clutch module.....................................................................................................................................................................................................................................................................................................................................................................................................................14261
2.4 Removing and installing clutch............................................................................................................................................................................................................................................................................................................................................................................................................................14264
2.4.1 Removing and installing Sachs version clutch........................................................................................................................................................................................................................................................................................................................................................................................................14264
2.4.2 Removing and installing LuK version clutch..........................................................................................................................................................................................................................................................................................................................................................................................................14268
2.5 Resetting adjuster ring in pressure plate, LuK version....................................................................................................................................................................................................................................................................................................................................................................................................14271
2.6 Renewing needle bearing/ball bearing for dual-mass flywheel...............................................................................................................................................................................................................................................................................................................................................................................................14273
34 – Controls, housing................................................................................................................................................................................................................................................................................................................................................................................................................................................14277
1 Transporting gearbox............................................................................................................................................................................................................................................................................................................................................................................................................................................14277
2 Securing to engine and gearbox support..........................................................................................................................................................................................................................................................................................................................................................................................................................14278
3 Dismantling and assembling gearbox..............................................................................................................................................................................................................................................................................................................................................................................................................................14280
3.1 Schematic overview - gearbox..............................................................................................................................................................................................................................................................................................................................................................................................................................14280
3.2 Exploded view - gearbox...................................................................................................................................................................................................................................................................................................................................................................................................................................14281
3.3 Exploded view - centre differential housing and centre differential.......................................................................................................................................................................................................................................................................................................................................................................................14282
3.4 Exploded view - gearbox cover, selector shaft.............................................................................................................................................................................................................................................................................................................................................................................................................14283
3.5 Exploded view - gear cluster, reverse gear wheel, selector mechanism......................................................................................................................................................................................................................................................................................................................................................................................14287
3.6 Exploded view - selector forks............................................................................................................................................................................................................................................................................................................................................................................................................................14289
3.7 Dismantling and assembling gearbox........................................................................................................................................................................................................................................................................................................................................................................................................................14291
3.8 Removing and installing selector shaft....................................................................................................................................................................................................................................................................................................................................................................................................................14307
4 Gearbox housing, clutch housing.................................................................................................................................................................................................................................................................................................................................................................................................................................14310
4.1 Exploded view - gearbox cover.............................................................................................................................................................................................................................................................................................................................................................................................................................14310
4.2 Exploded view - gearbox housing...........................................................................................................................................................................................................................................................................................................................................................................................................................14312
4.3 Servicing gearbox cover...................................................................................................................................................................................................................................................................................................................................................................................................................................14314
4.4 Servicing gearbox housing.................................................................................................................................................................................................................................................................................................................................................................................................................................14322
35 – Gears, shafts....................................................................................................................................................................................................................................................................................................................................................................................................................................................14326
1 Dismantling and assembling gears and shafts.....................................................................................................................................................................................................................................................................................................................................................................................................................14326
1.1 Exploded view - gear cluster..............................................................................................................................................................................................................................................................................................................................................................................................................................14326
1.2 Dismantling and assembling gear cluster...................................................................................................................................................................................................................................................................................................................................................................................................................14328
1.3 Exploded view - bearings for spur gear and centre differential............................................................................................................................................................................................................................................................................................................................................................................................14335
1.4 Servicing bearings for spur gear and centre differential..................................................................................................................................................................................................................................................................................................................................................................................................14337
1.5 Determining preload of tapered roller bearings for spur gear..............................................................................................................................................................................................................................................................................................................................................................................................14343
1.6 Determining thickness of new shim “S6” for adjusting position of centre differential......................................................................................................................................................................................................................................................................................................................................................................14345
2 Input shaft.....................................................................................................................................................................................................................................................................................................................................................................................................................................................14347
2.1 Exploded view - input shaft...............................................................................................................................................................................................................................................................................................................................................................................................................................14347
2.2 Dismantling and assembling input shaft....................................................................................................................................................................................................................................................................................................................................................................................................................14351
2.3 Allocation of 3rd - 6th gear synchro-rings to locking collars.............................................................................................................................................................................................................................................................................................................................................................................................14360
2.4 Checking 3rd - 6th gear synchro-rings for wear............................................................................................................................................................................................................................................................................................................................................................................................................14361
3 Output shaft....................................................................................................................................................................................................................................................................................................................................................................................................................................................14362
3.1 Exploded view - output shaft..............................................................................................................................................................................................................................................................................................................................................................................................................................14362
3.2 Dismantling and assembling output shaft...................................................................................................................................................................................................................................................................................................................................................................................................................14366
39 – Final drive - differential.......................................................................................................................................................................................................................................................................................................................................................................................................................................14372
1 Oil seals.......................................................................................................................................................................................................................................................................................................................................................................................................................................................14372
1.1 Overview of fitting locations - oil seals.................................................................................................................................................................................................................................................................................................................................................................................................................14372
1.2 Renewing oil seal (right-side)............................................................................................................................................................................................................................................................................................................................................................................................................................14373
1.3 Renewing oil seal (left-side).............................................................................................................................................................................................................................................................................................................................................................................................................................14375
1.4 Renewing input shaft oil seal.............................................................................................................................................................................................................................................................................................................................................................................................................................14379
2 Final drive.....................................................................................................................................................................................................................................................................................................................................................................................................................................................14381
2.1 Exploded view - final drive...............................................................................................................................................................................................................................................................................................................................................................................................................................14381
3 Differential....................................................................................................................................................................................................................................................................................................................................................................................................................................................14383
3.1 Exploded view - differential..............................................................................................................................................................................................................................................................................................................................................................................................................................14383
3.2 Removing and installing flange shaft (right-side).........................................................................................................................................................................................................................................................................................................................................................................................................14385
3.3 Removing and installing flange shaft (left-side)..........................................................................................................................................................................................................................................................................................................................................................................................................14387
3.4 Checking and adjusting preload of ball bearing for flange shaft (left-side)...............................................................................................................................................................................................................................................................................................................................................................................14391
3.4.1 Checking preload of ball bearing for flange shaft (left-side) - vehicles with vehicle ID No. up to 8K0BA088680 or 8FXBN009589.......................................................................................................................................................................................................................................................................................................................14391
3.4.2 Optimising preload of ball bearing for flange shaft (left-side) - vehicles with vehicle ID No. up to 8K0BA088680 or 8FXBN009589.....................................................................................................................................................................................................................................................................................................................14392
3.4.3 Adjusting preload of ball bearing for flange shaft (left-side) - vehicles with vehicle ID No. up to 8K0BA088680 or 8FXBN009589......................................................................................................................................................................................................................................................................................................................14393
3.5 Renewing mounting bracket and ball bearing for flange shaft (left-side)...................................................................................................................................................................................................................................................................................................................................................................................14396
3.6 Removing and installing differential......................................................................................................................................................................................................................................................................................................................................................................................................................14398
3.7 Renewing cover for final drive............................................................................................................................................................................................................................................................................................................................................................................................................................14400
3.7.1 Renewing cover for final drive, version with tapered roller bearings up to gearbox manufacturing date 14 08 11......................................................................................................................................................................................................................................................................................................................................14400
3.7.2 Renewing cover for final drive, version with angular contact ball bearing (high-efficiency bearing) from gearbox manufacturing date 15 08 11 onwards................................................................................................................................................................................................................................................................................................14407
3.8 Dismantling and assembling differential...................................................................................................................................................................................................................................................................................................................................................................................................................14412
3.9 Adjusting differential....................................................................................................................................................................................................................................................................................................................................................................................................................................14420
4 Centre differential.............................................................................................................................................................................................................................................................................................................................................................................................................................................14429
4.1 Exploded view - centre differential housing...............................................................................................................................................................................................................................................................................................................................................................................................................14429
4.1.1 Exploded view - centre differential housing with flange shaft (bolted propshaft)....................................................................................................................................................................................................................................................................................................................................................................14429
4.1.2 Exploded view - centre differential housing with rear splined shaft (propshaft with splines on gearbox end).........................................................................................................................................................................................................................................................................................................................................14431
4.2 Removing and installing centre differential housing.......................................................................................................................................................................................................................................................................................................................................................................................................14433
4.2.1 Removing and installing centre differential housing - bolted propshaft..............................................................................................................................................................................................................................................................................................................................................................................14433
4.2.2 Removing and installing centre differential housing - propshaft with splines........................................................................................................................................................................................................................................................................................................................................................................14436
4.3 Servicing centre differential housing.....................................................................................................................................................................................................................................................................................................................................................................................................................14438
4.3.1 Removing and installing rear flange shaft, oil seal and ball bearing................................................................................................................................................................................................................................................................................................................................................................................14438
4.3.2 Removing and installing rear splined shaft, oil seal and ball bearing...............................................................................................................................................................................................................................................................................................................................................................................14441
4.3.3 Pressing vibration damper onto rear splined shaft...................................................................................................................................................................................................................................................................................................................................................................................................14445
4.4 Renewing oil seal for rear splined shaft..................................................................................................................................................................................................................................................................................................................................................................................................................14446
4.4.1 Renewing oil seal for rear splined shaft - rear splined shaft without vibration damper..............................................................................................................................................................................................................................................................................................................................................................14446
4.4.2 Renewing oil seal for rear splined shaft - rear splined shaft with vibration damper.................................................................................................................................................................................................................................................................................................................................................................14448
Servicing_6-speed_manual_gearbox_0B3__front-wheel_drive...................................................................................................................................................................................................................................................................................................................................................................................................................14449
00 – Technical data...................................................................................................................................................................................................................................................................................................................................................................................................................................................14453
1 Identification..................................................................................................................................................................................................................................................................................................................................................................................................................................................14453
1.1 Gearbox identification....................................................................................................................................................................................................................................................................................................................................................................................................................................14453
2 Repair instructions.............................................................................................................................................................................................................................................................................................................................................................................................................................................14454
2.1 General repair instructions...............................................................................................................................................................................................................................................................................................................................................................................................................................14454
30 – Clutch...........................................................................................................................................................................................................................................................................................................................................................................................................................................................14459
1 Clutch mechanism................................................................................................................................................................................................................................................................................................................................................................................................................................................14459
1.1 Exploded view - clutch release mechanism..................................................................................................................................................................................................................................................................................................................................................................................................................14459
1.2 Servicing clutch release mechanism........................................................................................................................................................................................................................................................................................................................................................................................................................14461
2 Clutch..........................................................................................................................................................................................................................................................................................................................................................................................................................................................14462
2.1 General notes on clutch...................................................................................................................................................................................................................................................................................................................................................................................................................................14462
2.2 Exploded view - clutch unit...............................................................................................................................................................................................................................................................................................................................................................................................................................14465
2.3 Removing and installing clutch module.....................................................................................................................................................................................................................................................................................................................................................................................................................14468
2.4 Removing and installing clutch............................................................................................................................................................................................................................................................................................................................................................................................................................14472
2.5 Resetting adjuster ring in pressure plate.................................................................................................................................................................................................................................................................................................................................................................................................................14476
2.6 Renewing needle bearing for dual-mass flywheel............................................................................................................................................................................................................................................................................................................................................................................................................14478
34 – Controls, housing................................................................................................................................................................................................................................................................................................................................................................................................................................................14482
1 Transporting gearbox............................................................................................................................................................................................................................................................................................................................................................................................................................................14482
2 Securing to engine and gearbox support..........................................................................................................................................................................................................................................................................................................................................................................................................................14483
3 Dismantling and assembling gearbox..............................................................................................................................................................................................................................................................................................................................................................................................................................14485
3.1 Schematic overview - gearbox..............................................................................................................................................................................................................................................................................................................................................................................................................................14485
3.2 Exploded view - gearbox...................................................................................................................................................................................................................................................................................................................................................................................................................................14486
3.3 Exploded view - gear cluster, reverse gear wheel, selector mechanism......................................................................................................................................................................................................................................................................................................................................................................................14489
3.4 Exploded view - selector forks............................................................................................................................................................................................................................................................................................................................................................................................................................14490
3.5 Dismantling and assembling gearbox........................................................................................................................................................................................................................................................................................................................................................................................................................14491
3.6 Removing and installing selector shaft....................................................................................................................................................................................................................................................................................................................................................................................................................14505
4 Gearbox housing, clutch housing.................................................................................................................................................................................................................................................................................................................................................................................................................................14508
4.1 Exploded view - end cover.................................................................................................................................................................................................................................................................................................................................................................................................................................14508
4.2 Exploded view - gearbox cover.............................................................................................................................................................................................................................................................................................................................................................................................................................14509
4.3 Exploded view - gearbox housing...........................................................................................................................................................................................................................................................................................................................................................................................................................14511
4.4 Servicing end cover.......................................................................................................................................................................................................................................................................................................................................................................................................................................14513
4.5 Servicing gearbox cover...................................................................................................................................................................................................................................................................................................................................................................................................................................14515
4.6 Servicing gearbox housing.................................................................................................................................................................................................................................................................................................................................................................................................................................14522
35 – Gears, shafts....................................................................................................................................................................................................................................................................................................................................................................................................................................................14526
1 Dismantling and assembling gears and shafts.....................................................................................................................................................................................................................................................................................................................................................................................................................14526
1.1 Exploded view - gear cluster..............................................................................................................................................................................................................................................................................................................................................................................................................................14526
1.2 Dismantling and assembling gear cluster...................................................................................................................................................................................................................................................................................................................................................................................................................14528
1.3 Servicing bearings for spur gear..........................................................................................................................................................................................................................................................................................................................................................................................................................14533
1.4 Determining preload of tapered roller bearings for spur gear..............................................................................................................................................................................................................................................................................................................................................................................................14536
2 Input shaft.....................................................................................................................................................................................................................................................................................................................................................................................................................................................14539
2.1 Exploded view - input shaft...............................................................................................................................................................................................................................................................................................................................................................................................................................14539
2.2 Dismantling and assembling input shaft....................................................................................................................................................................................................................................................................................................................................................................................................................14542
3 Output shaft....................................................................................................................................................................................................................................................................................................................................................................................................................................................14552
3.1 Exploded view - output shaft..............................................................................................................................................................................................................................................................................................................................................................................................................................14552
3.2 Dismantling and assembling output shaft...................................................................................................................................................................................................................................................................................................................................................................................................................14557
39 – Final drive - differential.......................................................................................................................................................................................................................................................................................................................................................................................................................................14562
1 Final drive.....................................................................................................................................................................................................................................................................................................................................................................................................................................................14562
1.1 Exploded view - final drive...............................................................................................................................................................................................................................................................................................................................................................................................................................14562
1.2 Renewing cover for final drive............................................................................................................................................................................................................................................................................................................................................................................................................................14563
2 Oil seals.......................................................................................................................................................................................................................................................................................................................................................................................................................................................14569
2.1 Renewing oil seal (left-side).............................................................................................................................................................................................................................................................................................................................................................................................................................14569
2.2 Renewing oil seal (right-side)............................................................................................................................................................................................................................................................................................................................................................................................................................14574
2.3 Renewing input shaft oil seal.............................................................................................................................................................................................................................................................................................................................................................................................................................14576
3 Differential....................................................................................................................................................................................................................................................................................................................................................................................................................................................14578
3.1 Renewing mounting bracket and ball bearing for flange shaft (left-side)...................................................................................................................................................................................................................................................................................................................................................................................14578
Servicing_6-speed_manual_gearbox_0B4__four-wheel_drive....................................................................................................................................................................................................................................................................................................................................................................................................................14581
00 – Technical data...................................................................................................................................................................................................................................................................................................................................................................................................................................................14585
1 Identification..................................................................................................................................................................................................................................................................................................................................................................................................................................................14585
1.1 Gearbox identification....................................................................................................................................................................................................................................................................................................................................................................................................................................14585
2 Repair instructions.............................................................................................................................................................................................................................................................................................................................................................................................................................................14586
2.1 General repair instructions...............................................................................................................................................................................................................................................................................................................................................................................................................................14586
30 – Clutch...........................................................................................................................................................................................................................................................................................................................................................................................................................................................14592
1 Clutch mechanism................................................................................................................................................................................................................................................................................................................................................................................................................................................14592
1.1 Exploded view - clutch release mechanism..................................................................................................................................................................................................................................................................................................................................................................................................................14592
1.2 Servicing clutch release mechanism........................................................................................................................................................................................................................................................................................................................................................................................................................14595
2 Clutch..........................................................................................................................................................................................................................................................................................................................................................................................................................................................14596
2.1 General notes on clutch...................................................................................................................................................................................................................................................................................................................................................................................................................................14596
2.2 Exploded view - clutch unit...............................................................................................................................................................................................................................................................................................................................................................................................................................14599
2.2.1 Exploded view - single-plate clutch (LuK version)...................................................................................................................................................................................................................................................................................................................................................................................................14599
2.2.2 Exploded view - twin-plate clutch...................................................................................................................................................................................................................................................................................................................................................................................................................14602
2.3 Removing and installing clutch module.....................................................................................................................................................................................................................................................................................................................................................................................................................14604
2.4 Removing and installing clutch............................................................................................................................................................................................................................................................................................................................................................................................................................14608
2.4.1 Removing and installing clutch - single-plate clutch, LuK version...................................................................................................................................................................................................................................................................................................................................................................................14608
2.4.2 Removing and installing clutch - twin-plate clutch..................................................................................................................................................................................................................................................................................................................................................................................................14612
2.5 Resetting adjuster ring in pressure plate.................................................................................................................................................................................................................................................................................................................................................................................................................14616
2.6 Renewing needle bearing for dual-mass flywheel............................................................................................................................................................................................................................................................................................................................................................................................................14618
34 – Controls, housing................................................................................................................................................................................................................................................................................................................................................................................................................................................14622
1 Transporting gearbox............................................................................................................................................................................................................................................................................................................................................................................................................................................14622
2 Securing to engine and gearbox support..........................................................................................................................................................................................................................................................................................................................................................................................................................14623
3 Dismantling and assembling gearbox..............................................................................................................................................................................................................................................................................................................................................................................................................................14625
3.1 Schematic overview - gearbox..............................................................................................................................................................................................................................................................................................................................................................................................................................14625
3.2 Exploded view - gearbox...................................................................................................................................................................................................................................................................................................................................................................................................................................14627
3.3 Exploded view - centre differential housing and centre differential.......................................................................................................................................................................................................................................................................................................................................................................................14628
3.4 Exploded view - gearbox cover, selector shaft.............................................................................................................................................................................................................................................................................................................................................................................................................14629
3.5 Exploded view - gear cluster, reverse gear wheel, selector mechanism......................................................................................................................................................................................................................................................................................................................................................................................14632
3.6 Exploded view - selector forks............................................................................................................................................................................................................................................................................................................................................................................................................................14633
3.7 Dismantling and assembling gearbox........................................................................................................................................................................................................................................................................................................................................................................................................................14633
3.8 Removing and installing selector shaft....................................................................................................................................................................................................................................................................................................................................................................................................................14647
4 Gearbox housing, clutch housing.................................................................................................................................................................................................................................................................................................................................................................................................................................14650
4.1 Exploded view - gearbox cover.............................................................................................................................................................................................................................................................................................................................................................................................................................14650
4.2 Exploded view - gearbox housing...........................................................................................................................................................................................................................................................................................................................................................................................................................14652
4.3 Servicing gearbox cover...................................................................................................................................................................................................................................................................................................................................................................................................................................14654
4.4 Servicing gearbox housing.................................................................................................................................................................................................................................................................................................................................................................................................................................14661
35 – Gears, shafts....................................................................................................................................................................................................................................................................................................................................................................................................................................................14665
1 Dismantling and assembling gears and shafts.....................................................................................................................................................................................................................................................................................................................................................................................................................14665
1.1 Exploded view - gear cluster..............................................................................................................................................................................................................................................................................................................................................................................................................................14665
1.2 Dismantling and assembling gear cluster...................................................................................................................................................................................................................................................................................................................................................................................................................14667
1.3 Exploded view - bearings for spur gear and centre differential............................................................................................................................................................................................................................................................................................................................................................................................14673
1.4 Servicing bearings for spur gear and centre differential..................................................................................................................................................................................................................................................................................................................................................................................................14674
1.5 Determining preload of tapered roller bearings for spur gear..............................................................................................................................................................................................................................................................................................................................................................................................14680
1.6 Re-determining preload of ball bearings for centre differential...........................................................................................................................................................................................................................................................................................................................................................................................14682
2 Input shaft.....................................................................................................................................................................................................................................................................................................................................................................................................................................................14685
2.1 Exploded view - input shaft...............................................................................................................................................................................................................................................................................................................................................................................................................................14685
2.2 Dismantling and assembling input shaft....................................................................................................................................................................................................................................................................................................................................................................................................................14688
3 Output shaft....................................................................................................................................................................................................................................................................................................................................................................................................................................................14698
3.1 Exploded view - output shaft..............................................................................................................................................................................................................................................................................................................................................................................................................................14698
3.2 Dismantling and assembling output shaft...................................................................................................................................................................................................................................................................................................................................................................................................................14703
39 – Final drive - differential.......................................................................................................................................................................................................................................................................................................................................................................................................................................14709
1 Final drive.....................................................................................................................................................................................................................................................................................................................................................................................................................................................14709
1.1 Exploded view - final drive...............................................................................................................................................................................................................................................................................................................................................................................................................................14709
1.2 Renewing cover for final drive............................................................................................................................................................................................................................................................................................................................................................................................................................14710
2 Oil seals.......................................................................................................................................................................................................................................................................................................................................................................................................................................................14716
2.1 Renewing oil seal (left-side).............................................................................................................................................................................................................................................................................................................................................................................................................................14716
2.2 Renewing oil seal (right-side)............................................................................................................................................................................................................................................................................................................................................................................................................................14721
2.3 Renewing input shaft oil seal.............................................................................................................................................................................................................................................................................................................................................................................................................................14723
2.3.1 Renewing input shaft oil seal - Audi A5 Coupé 2008 ► up to gearbox serial number 000760.............................................................................................................................................................................................................................................................................................................................................................14723
2.3.2 Renewing input shaft oil seal - Audi A4 2008 ►; Audi A5 Coupé 2008 ► from gearbox serial number 000761 onwards......................................................................................................................................................................................................................................................................................................................................14724
3 Differential....................................................................................................................................................................................................................................................................................................................................................................................................................................................14726
3.1 Renewing mounting bracket and ball bearing for flange shaft (left-side)...................................................................................................................................................................................................................................................................................................................................................................................14726
4 Centre differential.............................................................................................................................................................................................................................................................................................................................................................................................................................................14729
4.1 Exploded view - centre differential housing...............................................................................................................................................................................................................................................................................................................................................................................................................14729
4.2 Servicing centre differential housing.....................................................................................................................................................................................................................................................................................................................................................................................................................14730
Servicing_7-speed_dual_clutch_gearbox_0B5_(S_tronic)......................................................................................................................................................................................................................................................................................................................................................................................................................14733
00 – Technical data...................................................................................................................................................................................................................................................................................................................................................................................................................................................14737
1 Repair instructions.............................................................................................................................................................................................................................................................................................................................................................................................................................................14737
1.1 Rules for cleanliness.....................................................................................................................................................................................................................................................................................................................................................................................................................................14737
1.2 General repair instructions...............................................................................................................................................................................................................................................................................................................................................................................................................................14737
1.3 Contact corrosion.........................................................................................................................................................................................................................................................................................................................................................................................................................................14739
30 – Clutch...........................................................................................................................................................................................................................................................................................................................................................................................................................................................14740
1 Clutch..........................................................................................................................................................................................................................................................................................................................................................................................................................................................14740
1.1 Exploded view - flywheel and dual clutch..................................................................................................................................................................................................................................................................................................................................................................................................................14740
1.2 Removing and installing flywheel..........................................................................................................................................................................................................................................................................................................................................................................................................................14741
1.3 Removing dual clutch......................................................................................................................................................................................................................................................................................................................................................................................................................................14743
1.4 Installing dual clutch....................................................................................................................................................................................................................................................................................................................................................................................................................................14746
34 – Controls, housing................................................................................................................................................................................................................................................................................................................................................................................................................................................14749
1 Mechatronic unit................................................................................................................................................................................................................................................................................................................................................................................................................................................14749
1.1 Exploded view - mechatronic unit..........................................................................................................................................................................................................................................................................................................................................................................................................................14749
1.2 Removing and installing oil pan...........................................................................................................................................................................................................................................................................................................................................................................................................................14753
1.3 Removing and installing ATF filter........................................................................................................................................................................................................................................................................................................................................................................................................................14754
1.4 Removing and installing mechatronic unit..................................................................................................................................................................................................................................................................................................................................................................................................................14755
1.5 Exploded view - printed circuits for mechatronic unit.....................................................................................................................................................................................................................................................................................................................................................................................................14762
1.6 Removing and installing printed circuits for mechatronic unit.............................................................................................................................................................................................................................................................................................................................................................................................14764
1.7 Removing and installing exchangeable ATF filter...........................................................................................................................................................................................................................................................................................................................................................................................................14768
2 Transporting gearbox............................................................................................................................................................................................................................................................................................................................................................................................................................................14773
3 Dismantling and assembling gearbox..............................................................................................................................................................................................................................................................................................................................................................................................................................14775
3.1 Exploded view - gearbox...................................................................................................................................................................................................................................................................................................................................................................................................................................14775
3.2 Removing and installing sensor module with integrated senders and sensors -G612-, -G632-, -G676- and printed circuit 3....................................................................................................................................................................................................................................................................................................................................14777
3.3 Removing and installing oil pump and suction-jet pump.....................................................................................................................................................................................................................................................................................................................................................................................................14789
3.4 Renewing oil seals for partition in gearbox housing.......................................................................................................................................................................................................................................................................................................................................................................................................14792
4 Securing to engine and gearbox support..........................................................................................................................................................................................................................................................................................................................................................................................................................14795
5 ATF.............................................................................................................................................................................................................................................................................................................................................................................................................................................................14797
5.1 Exploded view - ATF drain, filler and inspection plugs....................................................................................................................................................................................................................................................................................................................................................................................................14797
5.2 Draining and filling ATF..................................................................................................................................................................................................................................................................................................................................................................................................................................14797
35 – Gears, shafts....................................................................................................................................................................................................................................................................................................................................................................................................................................................14800
1 Input shaft.....................................................................................................................................................................................................................................................................................................................................................................................................................................................14800
1.1 Renewing ball bearing for input shaft.....................................................................................................................................................................................................................................................................................................................................................................................................................14800
1.2 Renewing input shaft oil seal.............................................................................................................................................................................................................................................................................................................................................................................................................................14803
39 – Final drive - front differential.................................................................................................................................................................................................................................................................................................................................................................................................................................14805
1 Final drive.....................................................................................................................................................................................................................................................................................................................................................................................................................................................14805
1.1 Exploded view - final drive...............................................................................................................................................................................................................................................................................................................................................................................................................................14805
2 Gear oil........................................................................................................................................................................................................................................................................................................................................................................................................................................................14807
2.1 Exploded view - gear oil drain and inspection plugs.......................................................................................................................................................................................................................................................................................................................................................................................................14807
2.2 Draining and filling gear oil.............................................................................................................................................................................................................................................................................................................................................................................................................................14807
2.3 Removing and installing gearbox oil temperature sender 2 -G754-...........................................................................................................................................................................................................................................................................................................................................................................................14810
3 Oil seals.......................................................................................................................................................................................................................................................................................................................................................................................................................................................14812
3.1 Renewing oil seal (left-side).............................................................................................................................................................................................................................................................................................................................................................................................................................14812
3.2 Renewing oil seal (right-side)............................................................................................................................................................................................................................................................................................................................................................................................................................14814
3.3 Renewing selector shaft oil seal..........................................................................................................................................................................................................................................................................................................................................................................................................................14815
4 Differential....................................................................................................................................................................................................................................................................................................................................................................................................................................................14816
4.1 Removing and installing flange shaft (left-side)..........................................................................................................................................................................................................................................................................................................................................................................................................14816
4.2 Checking and adjusting preload of ball bearing for flange shaft (left-side)...............................................................................................................................................................................................................................................................................................................................................................................14818
4.2.1 Checking preload of ball bearing for flange shaft (left-side).......................................................................................................................................................................................................................................................................................................................................................................................14818
4.2.2 Optimising preload of ball bearing for flange shaft (left-side).....................................................................................................................................................................................................................................................................................................................................................................................14819
4.2.3 Adjusting preload of ball bearing for flange shaft (left-side)......................................................................................................................................................................................................................................................................................................................................................................................14820
4.3 Renewing mounting bracket and ball bearing for flange shaft (left-side)...................................................................................................................................................................................................................................................................................................................................................................................14824
4.4 Removing and installing flange shaft (right-side).........................................................................................................................................................................................................................................................................................................................................................................................................14826
5 Centre differential.............................................................................................................................................................................................................................................................................................................................................................................................................................................14829
5.1 Exploded view - centre differential housing...............................................................................................................................................................................................................................................................................................................................................................................................................14829
5.1.1 Exploded view - centre differential housing (bolted propshaft)......................................................................................................................................................................................................................................................................................................................................................................................14829
5.1.2 Exploded view - centre differential housing (propshaft with splines)................................................................................................................................................................................................................................................................................................................................................................................14831
5.2 Removing and installing centre differential housing.......................................................................................................................................................................................................................................................................................................................................................................................................14833
5.2.1 Removing and installing centre differential housing - bolted propshaft..............................................................................................................................................................................................................................................................................................................................................................................14833
5.2.2 Removing and installing centre differential housing - propshaft with splines........................................................................................................................................................................................................................................................................................................................................................................14837
5.3 Servicing centre differential housing.....................................................................................................................................................................................................................................................................................................................................................................................................................14840
5.3.1 Removing and installing rear flange shaft, oil seal and ball bearing................................................................................................................................................................................................................................................................................................................................................................................14840
5.3.2 Removing and installing rear splined shaft, oil seal and ball bearing...............................................................................................................................................................................................................................................................................................................................................................................14844
5.4 Renewing oil seal for rear splined shaft..................................................................................................................................................................................................................................................................................................................................................................................................................14848
5.4.1 Renewing oil seal for rear splined shaft - rear splined shaft without vibration damper..............................................................................................................................................................................................................................................................................................................................................................14848
5.4.2 Renewing oil seal for rear splined shaft - rear splined shaft with vibration damper.................................................................................................................................................................................................................................................................................................................................................................14851
Servicing_multitronic_0AW.................................................................................................................................................................................................................................................................................................................................................................................................................................................14852
00 – Technical data...................................................................................................................................................................................................................................................................................................................................................................................................................................................14856
1 Repair instructions.............................................................................................................................................................................................................................................................................................................................................................................................................................................14856
1.1 General repair instructions...............................................................................................................................................................................................................................................................................................................................................................................................................................14856
1.2 Contact corrosion.........................................................................................................................................................................................................................................................................................................................................................................................................................................14857
1.3 Rules for cleanliness.....................................................................................................................................................................................................................................................................................................................................................................................................................................14858
1.4 Common faults.............................................................................................................................................................................................................................................................................................................................................................................................................................................14858
37 – Controls, housing................................................................................................................................................................................................................................................................................................................................................................................................................................................14859
1 ATF.............................................................................................................................................................................................................................................................................................................................................................................................................................................................14859
1.1 Purging ATF...............................................................................................................................................................................................................................................................................................................................................................................................................................................14859
1.1.1 ATF purging procedure...............................................................................................................................................................................................................................................................................................................................................................................................................................14859
1.1.2 Draining ATF (for ATF purging procedure)............................................................................................................................................................................................................................................................................................................................................................................................................14860
1.1.3 Filling up with ATF (for ATF purging procedure).....................................................................................................................................................................................................................................................................................................................................................................................................14863
1.1.4 Road test (for ATF purging procedure)...............................................................................................................................................................................................................................................................................................................................................................................................................14866
2 Transporting gearbox............................................................................................................................................................................................................................................................................................................................................................................................................................................14869
3 Securing to engine and gearbox support..........................................................................................................................................................................................................................................................................................................................................................................................................................14870
38 – Gears, control...................................................................................................................................................................................................................................................................................................................................................................................................................................................14872
1 Dismantling and assembling gearbox..............................................................................................................................................................................................................................................................................................................................................................................................................................14872
1.1 Exploded view - dual-mass flywheel........................................................................................................................................................................................................................................................................................................................................................................................................................14872
1.2 Exploded view - end cover.................................................................................................................................................................................................................................................................................................................................................................................................................................14873
1.3 Exploded view - input shaft...............................................................................................................................................................................................................................................................................................................................................................................................................................14874
1.4 Removing and installing dual-mass flywheel................................................................................................................................................................................................................................................................................................................................................................................................................14874
1.5 Removing and installing end cover.........................................................................................................................................................................................................................................................................................................................................................................................................................14876
1.6 Cleaning selector shaft...................................................................................................................................................................................................................................................................................................................................................................................................................................14878
1.7 Modifying thrust piece -T40099- for use with multitronic gearbox 0AW, front-wheel drive...................................................................................................................................................................................................................................................................................................................................................................14879
1.8 Removing and installing input shaft.......................................................................................................................................................................................................................................................................................................................................................................................................................14879
1.9 Removing and installing input shaft cover.................................................................................................................................................................................................................................................................................................................................................................................................................14885
1.10 Renewing ball bearing for input shaft....................................................................................................................................................................................................................................................................................................................................................................................................................14890
2 Clutch..........................................................................................................................................................................................................................................................................................................................................................................................................................................................14894
2.1 Exploded view - reverse gear clutch.......................................................................................................................................................................................................................................................................................................................................................................................................................14894
2.2 Exploded view - input shaft with friction plates..........................................................................................................................................................................................................................................................................................................................................................................................................14895
2.3 Removing and installing reverse gear clutch and determining shim thicknesses..............................................................................................................................................................................................................................................................................................................................................................................14895
2.4 Dismantling and assembling input shaft....................................................................................................................................................................................................................................................................................................................................................................................................................14902
2.5 Adjusting input shaft and checking clearance..............................................................................................................................................................................................................................................................................................................................................................................................................14909
2.6 Assessing wear on input shaft.............................................................................................................................................................................................................................................................................................................................................................................................................................14915
39 – Final drive - differential.......................................................................................................................................................................................................................................................................................................................................................................................................................................14918
1 Final drive.....................................................................................................................................................................................................................................................................................................................................................................................................................................................14918
1.1 Exploded view - final drive...............................................................................................................................................................................................................................................................................................................................................................................................................................14918
2 Oil seals.......................................................................................................................................................................................................................................................................................................................................................................................................................................................14921
2.1 Renewing oil seal (left-side).............................................................................................................................................................................................................................................................................................................................................................................................................................14921
2.2 Renewing oil seal (right-side)............................................................................................................................................................................................................................................................................................................................................................................................................................14924
2.3 Renewing oil seal for input shaft.........................................................................................................................................................................................................................................................................................................................................................................................................................14925
2.4 Renewing selector shaft oil seal..........................................................................................................................................................................................................................................................................................................................................................................................................................14926
3 Differential....................................................................................................................................................................................................................................................................................................................................................................................................................................................14930
3.1 Removing and installing flange shaft (left-side)..........................................................................................................................................................................................................................................................................................................................................................................................................14930
3.2 Removing and installing flange shaft (right-side).........................................................................................................................................................................................................................................................................................................................................................................................................14933
3.3 Preload of ball bearing for flange shaft (left-side)......................................................................................................................................................................................................................................................................................................................................................................................................14934
3.3.1 Checking preload of ball bearing for flange shaft (left-side).......................................................................................................................................................................................................................................................................................................................................................................................14934
3.3.2 Optimising preload of ball bearing for flange shaft (left-side).....................................................................................................................................................................................................................................................................................................................................................................................14935
3.3.3 Adjusting preload of ball bearing for flange shaft (left-side)......................................................................................................................................................................................................................................................................................................................................................................................14936
3.4 Renewing mounting bracket and ball bearing for flange shaft (left-side)...................................................................................................................................................................................................................................................................................................................................................................................14940
4 Gearbox control system..........................................................................................................................................................................................................................................................................................................................................................................................................................................14943
4.1 Removing and installing gearbox control unit..............................................................................................................................................................................................................................................................................................................................................................................................................14943
4.2 Removing and installing hydraulic control unit............................................................................................................................................................................................................................................................................................................................................................................................................14945
Simos_direct_petrol_injection_and_ignition_system_(6-cyl__3_0_ltr__TFSI_4-valve)..........................................................................................................................................................................................................................................................................................................................................................................................14952
24 – Mixture preparation - injection..................................................................................................................................................................................................................................................................................................................................................................................................................................14956
1 Safety precautions and rules for cleanliness....................................................................................................................................................................................................................................................................................................................................................................................................................14956
1.1 General notes on self-diagnosis...........................................................................................................................................................................................................................................................................................................................................................................................................................14956
1.2 Safety precautions........................................................................................................................................................................................................................................................................................................................................................................................................................................14957
1.3 Rules for cleanliness and instructions for working on fuel system.........................................................................................................................................................................................................................................................................................................................................................................................14958
1.4 Reducing pressure in high-pressure section of injection system............................................................................................................................................................................................................................................................................................................................................................................................14958
1.5 Checking for leaks in the fuel system.....................................................................................................................................................................................................................................................................................................................................................................................................................14960
1.6 Checking vacuum system....................................................................................................................................................................................................................................................................................................................................................................................................................................14961
2 Injection system................................................................................................................................................................................................................................................................................................................................................................................................................................................14962
2.1 Test data.................................................................................................................................................................................................................................................................................................................................................................................................................................................14962
2.2 Overview of fitting locations.............................................................................................................................................................................................................................................................................................................................................................................................................................14962
2.3 Air cleaner - exploded view...............................................................................................................................................................................................................................................................................................................................................................................................................................14972
2.4 Removing and installing air filter element................................................................................................................................................................................................................................................................................................................................................................................................................14974
2.5 Intake manifold (bottom section) - exploded view..........................................................................................................................................................................................................................................................................................................................................................................................................14975
2.6 Removing and installing intake manifold (bottom section) with fuel rail...................................................................................................................................................................................................................................................................................................................................................................................14978
2.7 Removing and installing throttle valve module -J338-......................................................................................................................................................................................................................................................................................................................................................................................................14980
2.8 Removing and installing regulating flap control unit -J808-...............................................................................................................................................................................................................................................................................................................................................................................................14982
2.9 Removing and installing injectors.........................................................................................................................................................................................................................................................................................................................................................................................................................14982
2.10 Checking fuel pressure and residual pressure (up to high-pressure pump)..................................................................................................................................................................................................................................................................................................................................................................................14986
2.11 High-pressure pump - exploded view.......................................................................................................................................................................................................................................................................................................................................................................................................................14990
2.12 Removing and installing high-pressure pipe...............................................................................................................................................................................................................................................................................................................................................................................................................14992
2.13 Removing and installing high-pressure pump...............................................................................................................................................................................................................................................................................................................................................................................................................14994
2.14 Lambda probes - overview.................................................................................................................................................................................................................................................................................................................................................................................................................................14996
2.15 Removing and installing Lambda probe -G39-...............................................................................................................................................................................................................................................................................................................................................................................................................14997
2.16 Removing and installing Lambda probe after catalytic converter -G130-....................................................................................................................................................................................................................................................................................................................................................................................14999
2.17 Removing and installing Lambda probe 2 -G108-............................................................................................................................................................................................................................................................................................................................................................................................................15001
2.18 Removing and installing Lambda probe 2 after catalytic converter -G131-..................................................................................................................................................................................................................................................................................................................................................................................15003
3 Engine control unit.............................................................................................................................................................................................................................................................................................................................................................................................................................................15006
3.1 Wiring and component check with test box -V.A.G 1598/42-..................................................................................................................................................................................................................................................................................................................................................................................................15006
3.2 Removing and installing engine control unit...............................................................................................................................................................................................................................................................................................................................................................................................................15008
28 – Ignition system..................................................................................................................................................................................................................................................................................................................................................................................................................................................15012
1 General notes and safety precautions............................................................................................................................................................................................................................................................................................................................................................................................................................15012
1.1 General notes on ignition system..........................................................................................................................................................................................................................................................................................................................................................................................................................15012
1.2 Safety precautions........................................................................................................................................................................................................................................................................................................................................................................................................................................15012
2 Servicing ignition system.......................................................................................................................................................................................................................................................................................................................................................................................................................................15014
2.1 Test data.................................................................................................................................................................................................................................................................................................................................................................................................................................................15014
2.2 Ignition system - exploded view...........................................................................................................................................................................................................................................................................................................................................................................................................................15014
2.3 Removing and installing ignition coils....................................................................................................................................................................................................................................................................................................................................................................................................................15015
2.4 Removing and installing knock sensors -G61- / -G66-.......................................................................................................................................................................................................................................................................................................................................................................................................15017
2.5 Removing and installing Hall senders -G40- / -G163-.......................................................................................................................................................................................................................................................................................................................................................................................................15018
2.6 Removing and installing engine speed sender -G28-.........................................................................................................................................................................................................................................................................................................................................................................................................15019
Simos_direct_petrol_injection_and_ignition_system_(6-cyl__3_2_ltr__4-valve)...............................................................................................................................................................................................................................................................................................................................................................................................15020
24 – Mixture preparation - injection..................................................................................................................................................................................................................................................................................................................................................................................................................................15024
1 Safety precautions and rules for cleanliness....................................................................................................................................................................................................................................................................................................................................................................................................................15024
1.1 General notes on self-diagnosis...........................................................................................................................................................................................................................................................................................................................................................................................................................15024
1.2 Safety precautions........................................................................................................................................................................................................................................................................................................................................................................................................................................15024
1.3 Rules for cleanliness when working on the injection system................................................................................................................................................................................................................................................................................................................................................................................................15025
1.4 Important: Required procedure prior to opening high-pressure injection system.............................................................................................................................................................................................................................................................................................................................................................................15026
1.5 Checking for leaks in fuel system.........................................................................................................................................................................................................................................................................................................................................................................................................................15027
1.6 Checking vacuum system....................................................................................................................................................................................................................................................................................................................................................................................................................................15027
2 Injection system................................................................................................................................................................................................................................................................................................................................................................................................................................................15029
2.1 Technical data............................................................................................................................................................................................................................................................................................................................................................................................................................................15029
2.2 Overview of fitting locations.............................................................................................................................................................................................................................................................................................................................................................................................................................15029
2.3 Air cleaner - exploded view...............................................................................................................................................................................................................................................................................................................................................................................................................................15039
2.4 Removing and installing air filter element................................................................................................................................................................................................................................................................................................................................................................................................................15040
2.5 Removing air cleaner housing (bottom section).............................................................................................................................................................................................................................................................................................................................................................................................................15042
2.6 Intake manifold (top section) - exploded view.............................................................................................................................................................................................................................................................................................................................................................................................................15044
2.7 Intake manifold (bottom section) with fuel rail - exploded view...........................................................................................................................................................................................................................................................................................................................................................................................15047
2.8 Removing and installing intake manifold (top section).....................................................................................................................................................................................................................................................................................................................................................................................................15048
2.9 Removing and installing intake manifold (bottom section) with fuel rail...................................................................................................................................................................................................................................................................................................................................................................................15050
2.10 Removing and installing fuel pressure sender -G247-......................................................................................................................................................................................................................................................................................................................................................................................................15052
2.11 Checking fuel pressure and residual pressure (up to high-pressure pump)..................................................................................................................................................................................................................................................................................................................................................................................15052
2.12 High-pressure pump - exploded view.......................................................................................................................................................................................................................................................................................................................................................................................................................15056
2.13 Removing and installing high-pressure pump...............................................................................................................................................................................................................................................................................................................................................................................................................15058
2.14 Removing and installing injectors........................................................................................................................................................................................................................................................................................................................................................................................................................15062
2.15 Removing and installing high-pressure pipes..............................................................................................................................................................................................................................................................................................................................................................................................................15066
2.16 Lambda probes - overview.................................................................................................................................................................................................................................................................................................................................................................................................................................15067
2.17 Removing and installing Lambda probe -G39- before catalytic converter - bank 1 (right-side)..............................................................................................................................................................................................................................................................................................................................................................15068
2.18 Removing and installing Lambda probe after catalytic converter -G130- - bank 1 (right-side)..............................................................................................................................................................................................................................................................................................................................................................15070
2.19 Removing and installing Lambda probe 2 -G108- before catalytic converter - bank 2 (left-side)............................................................................................................................................................................................................................................................................................................................................................15072
2.20 Removing and installing Lambda probe 2 after catalytic converter -G131- - bank 2 (left-side).............................................................................................................................................................................................................................................................................................................................................................15074
3 Engine control unit.............................................................................................................................................................................................................................................................................................................................................................................................................................................15077
3.1 Wiring and component check with test box -V.A.G 1598/42-..................................................................................................................................................................................................................................................................................................................................................................................................15077
3.2 Removing and installing engine control unit -J623-........................................................................................................................................................................................................................................................................................................................................................................................................15078
28 – Ignition system..................................................................................................................................................................................................................................................................................................................................................................................................................................................15082
1 General notes and safety precautions............................................................................................................................................................................................................................................................................................................................................................................................................................15082
1.1 General notes on ignition system..........................................................................................................................................................................................................................................................................................................................................................................................................................15082
1.2 Safety precautions........................................................................................................................................................................................................................................................................................................................................................................................................................................15082
2 Servicing ignition system.......................................................................................................................................................................................................................................................................................................................................................................................................................................15084
2.1 Test data.................................................................................................................................................................................................................................................................................................................................................................................................................................................15084
2.2 Ignition system - exploded view...........................................................................................................................................................................................................................................................................................................................................................................................................................15084
2.3 Removing and installing ignition coils....................................................................................................................................................................................................................................................................................................................................................................................................................15085
2.4 Removing and installing knock sensors.....................................................................................................................................................................................................................................................................................................................................................................................................................15087
2.5 Removing and installing Hall sender.......................................................................................................................................................................................................................................................................................................................................................................................................................15088
2.6 Removing and installing engine speed sender -G28-.........................................................................................................................................................................................................................................................................................................................................................................................................15089
Specifications_for_testing_the_braking_force..............................................................................................................................................................................................................................................................................................................................................................................................................................15090
00 – Technical data...................................................................................................................................................................................................................................................................................................................................................................................................................................................15094
1 Testing the braking force.......................................................................................................................................................................................................................................................................................................................................................................................................................................15094
1.1 Legal requirements........................................................................................................................................................................................................................................................................................................................................................................................................................................15094
1.2 Specifications for testing the braking force..............................................................................................................................................................................................................................................................................................................................................................................................................15094
System_description_-_adaptive_cruise_control..............................................................................................................................................................................................................................................................................................................................................................................................................................15096
01 – Self-diagnosis, electrical checks................................................................................................................................................................................................................................................................................................................................................................................................................................15100
1 General notes on „adaptive cruise control“ (ACC)................................................................................................................................................................................................................................................................................................................................................................................................................15100
1.1 Technical data............................................................................................................................................................................................................................................................................................................................................................................................................................................15101
1.2 Components used...........................................................................................................................................................................................................................................................................................................................................................................................................................................15101
1.3 General notes on information exchange.....................................................................................................................................................................................................................................................................................................................................................................................................................15103
1.4 Definition of terms and abbreviations.....................................................................................................................................................................................................................................................................................................................................................................................................................15104
2 Function: No vehicle in front, cruise control...................................................................................................................................................................................................................................................................................................................................................................................................................15106
2.1 General notes, components used............................................................................................................................................................................................................................................................................................................................................................................................................................15106
2.2 Description...............................................................................................................................................................................................................................................................................................................................................................................................................................................15106
2.3 Notes for service.........................................................................................................................................................................................................................................................................................................................................................................................................................................15106
3 Function: Vehicle in front......................................................................................................................................................................................................................................................................................................................................................................................................................................15107
3.1 General notes, components used............................................................................................................................................................................................................................................................................................................................................................................................................................15107
3.2 Description...............................................................................................................................................................................................................................................................................................................................................................................................................................................15108
3.3 Notes for service.........................................................................................................................................................................................................................................................................................................................................................................................................................................15109
System_description_-_entry_and_start_authorisation........................................................................................................................................................................................................................................................................................................................................................................................................................15110
01 – Self-diagnosis, electrical checks................................................................................................................................................................................................................................................................................................................................................................................................................................15114
1 General notes on entry and start authorisation function.........................................................................................................................................................................................................................................................................................................................................................................................................15114
1.1 General functions.........................................................................................................................................................................................................................................................................................................................................................................................................................................15114
1.2 Entry and start authorisation: main functions.............................................................................................................................................................................................................................................................................................................................................................................................................15114
1.3 Note for service..........................................................................................................................................................................................................................................................................................................................................................................................................................................15114
2 Immobilizer V: function.........................................................................................................................................................................................................................................................................................................................................................................................................................................15115
2.1 General notes on immobilizer V............................................................................................................................................................................................................................................................................................................................................................................................................................15115
2.2 System overview for immobilizer V.........................................................................................................................................................................................................................................................................................................................................................................................................................15115
2.3 Designation of components of immobilizer V................................................................................................................................................................................................................................................................................................................................................................................................................15116
2.4 Adaption concept for immobilizer V........................................................................................................................................................................................................................................................................................................................................................................................................................15117
2.4.1 Functional checks to determine states of control units..............................................................................................................................................................................................................................................................................................................................................................................................15117
2.4.2 Notes for service...................................................................................................................................................................................................................................................................................................................................................................................................................................15118
3 Terminal control and starting the engine........................................................................................................................................................................................................................................................................................................................................................................................................................15119
3.1 General notes on terminal control and starting the engine.................................................................................................................................................................................................................................................................................................................................................................................................15119
3.2 Conditions for terminal 15 on.............................................................................................................................................................................................................................................................................................................................................................................................................................15119
3.3 Conditions for starting the engine........................................................................................................................................................................................................................................................................................................................................................................................................................15119
3.4 Starting with vehicle key.................................................................................................................................................................................................................................................................................................................................................................................................................................15119
3.5 Starting engine with „Advanced Key“.......................................................................................................................................................................................................................................................................................................................................................................................................................15120
3.6 Ignition key withdrawal lock..............................................................................................................................................................................................................................................................................................................................................................................................................................15121
3.7 Note for service..........................................................................................................................................................................................................................................................................................................................................................................................................................................15122
4 Locking the steering column.....................................................................................................................................................................................................................................................................................................................................................................................................................................15123
4.1 General notes on the steering column lock.................................................................................................................................................................................................................................................................................................................................................................................................................15123
4.2 Locking and unlocking the steering column.................................................................................................................................................................................................................................................................................................................................................................................................................15123
4.3 System overview for steering column lock..................................................................................................................................................................................................................................................................................................................................................................................................................15123
4.4 Note for service..........................................................................................................................................................................................................................................................................................................................................................................................................................................15124
5 Advanced Key....................................................................................................................................................................................................................................................................................................................................................................................................................................................15125
5.1 General information on entry and start authorisation control unit „Advanced Key“..........................................................................................................................................................................................................................................................................................................................................................................15125
5.2 System overview of entry and start authorisation control unit „Advanced Key“..............................................................................................................................................................................................................................................................................................................................................................................15125
5.2.1 System overview for „Advanced Key“ (2-door vehicles)................................................................................................................................................................................................................................................................................................................................................................................................15125
5.2.2 System overview for „Advanced Key“ (4-door vehicles)................................................................................................................................................................................................................................................................................................................................................................................................15126
5.3 Note for service - „Advanced Key“ diagnosis...............................................................................................................................................................................................................................................................................................................................................................................................................15126
System_description_-_Extended_service_interval............................................................................................................................................................................................................................................................................................................................................................................................................................15128
01 – Self-diagnosis, electrical checks................................................................................................................................................................................................................................................................................................................................................................................................................................15132
1 General notes...................................................................................................................................................................................................................................................................................................................................................................................................................................................15132
2 Components used to calculate an oil change service date.........................................................................................................................................................................................................................................................................................................................................................................................................15133
3 Detailed description............................................................................................................................................................................................................................................................................................................................................................................................................................................15134
3.1 Longlife interval and fixed interval......................................................................................................................................................................................................................................................................................................................................................................................................................15134
3.2 Calculation of oil change service date....................................................................................................................................................................................................................................................................................................................................................................................................................15134
3.3 Display of information on oil change and inspection services..............................................................................................................................................................................................................................................................................................................................................................................................15135
3.4 Reminder of and request for oil change or inspection......................................................................................................................................................................................................................................................................................................................................................................................................15136
3.5 Resetting the service interval display....................................................................................................................................................................................................................................................................................................................................................................................................................15136
3.6 Information for service...................................................................................................................................................................................................................................................................................................................................................................................................................................15137
System_description_-_exterior_lights......................................................................................................................................................................................................................................................................................................................................................................................................................................15138
01 – Self-diagnosis, electrical checks................................................................................................................................................................................................................................................................................................................................................................................................................................15142
1 General notes on the exterior light functions...................................................................................................................................................................................................................................................................................................................................................................................................................15142
1.1 General notes and technical data..........................................................................................................................................................................................................................................................................................................................................................................................................................15142
1.2 Components used...........................................................................................................................................................................................................................................................................................................................................................................................................................................15142
2 Switching on the dipped beam headlights automatically...........................................................................................................................................................................................................................................................................................................................................................................................................15143
2.1 General notes and components used.........................................................................................................................................................................................................................................................................................................................................................................................................................15143
2.2 Description...............................................................................................................................................................................................................................................................................................................................................................................................................................................15143
2.3 Notes for service.........................................................................................................................................................................................................................................................................................................................................................................................................................................15144
3 Switching on the main beam headlights automatically (main beam assist)..........................................................................................................................................................................................................................................................................................................................................................................................15145
3.1 General notes and components used.........................................................................................................................................................................................................................................................................................................................................................................................................................15145
3.2 Description...............................................................................................................................................................................................................................................................................................................................................................................................................................................15145
3.3 Notes for service.........................................................................................................................................................................................................................................................................................................................................................................................................................................15147
4 Switching on the lights via the light switch -E1-...............................................................................................................................................................................................................................................................................................................................................................................................................15148
4.1 General notes and components used.........................................................................................................................................................................................................................................................................................................................................................................................................................15148
4.2 Description...............................................................................................................................................................................................................................................................................................................................................................................................................................................15148
4.3 Notes for service.........................................................................................................................................................................................................................................................................................................................................................................................................................................15149
5 Activation of the brake lights..................................................................................................................................................................................................................................................................................................................................................................................................................................15150
5.1 General notes and components used.........................................................................................................................................................................................................................................................................................................................................................................................................................15150
5.2 Description...............................................................................................................................................................................................................................................................................................................................................................................................................................................15150
5.3 Notes for service.........................................................................................................................................................................................................................................................................................................................................................................................................................................15150
6 Flashing functions..............................................................................................................................................................................................................................................................................................................................................................................................................................................15151
6.1 General notes and components used.........................................................................................................................................................................................................................................................................................................................................................................................................................15151
6.2 Description...............................................................................................................................................................................................................................................................................................................................................................................................................................................15151
6.3 Notes for service.........................................................................................................................................................................................................................................................................................................................................................................................................................................15152
7 Coming home.....................................................................................................................................................................................................................................................................................................................................................................................................................................................15153
7.1 General notes and components used.........................................................................................................................................................................................................................................................................................................................................................................................................................15153
7.2 Description...............................................................................................................................................................................................................................................................................................................................................................................................................................................15153
7.3 Notes for service.........................................................................................................................................................................................................................................................................................................................................................................................................................................15153
8 Leaving home....................................................................................................................................................................................................................................................................................................................................................................................................................................................15155
8.1 General notes and components used.........................................................................................................................................................................................................................................................................................................................................................................................................................15155
8.2 Description...............................................................................................................................................................................................................................................................................................................................................................................................................................................15155
8.3 Notes for service.........................................................................................................................................................................................................................................................................................................................................................................................................................................15155
9 Switching on the reversing lights...............................................................................................................................................................................................................................................................................................................................................................................................................................15157
9.1 General notes and components used.........................................................................................................................................................................................................................................................................................................................................................................................................................15157
9.2 Description...............................................................................................................................................................................................................................................................................................................................................................................................................................................15157
9.3 Notes for service.........................................................................................................................................................................................................................................................................................................................................................................................................................................15158
10 Number plate light.............................................................................................................................................................................................................................................................................................................................................................................................................................................15159
11 Renewing bulbs.................................................................................................................................................................................................................................................................................................................................................................................................................................................15160
12 Headlight range control........................................................................................................................................................................................................................................................................................................................................................................................................................................15161
12.1 General notes and components used........................................................................................................................................................................................................................................................................................................................................................................................................................15161
12.2 Description of manual headlight range control............................................................................................................................................................................................................................................................................................................................................................................................................15161
12.3 Description of automatic dynamic headlight range control.................................................................................................................................................................................................................................................................................................................................................................................................15161
12.4 Description of automatic dynamic headlight range control with AFS (cornering lights).....................................................................................................................................................................................................................................................................................................................................................................15162
12.5 Showroom mode............................................................................................................................................................................................................................................................................................................................................................................................................................................15162
12.6 Tourist mode.............................................................................................................................................................................................................................................................................................................................................................................................................................................15162
12.7 Notes for service........................................................................................................................................................................................................................................................................................................................................................................................................................................15163
System_description_-_Exterior_mirrors.....................................................................................................................................................................................................................................................................................................................................................................................................................................15164
01 – Self-diagnosis, electrical checks................................................................................................................................................................................................................................................................................................................................................................................................................................15168
1 General notes...................................................................................................................................................................................................................................................................................................................................................................................................................................................15168
2 Components used.................................................................................................................................................................................................................................................................................................................................................................................................................................................15169
3 Description.....................................................................................................................................................................................................................................................................................................................................................................................................................................................15170
4 Notes for service...............................................................................................................................................................................................................................................................................................................................................................................................................................................15172
System_description_-_infotainment_and_audio_output_(MOST).................................................................................................................................................................................................................................................................................................................................................................................................................15173
01 – Self-diagnosis, electrical checks................................................................................................................................................................................................................................................................................................................................................................................................................................15177
1 General information on audio output (MOST)......................................................................................................................................................................................................................................................................................................................................................................................................................15177
1.1 Definition of terms.......................................................................................................................................................................................................................................................................................................................................................................................................................................15177
1.2 Technical data............................................................................................................................................................................................................................................................................................................................................................................................................................................15178
1.3 Components used (MMI2G)...................................................................................................................................................................................................................................................................................................................................................................................................................................15181
1.4 Components used (MMI3G)...................................................................................................................................................................................................................................................................................................................................................................................................................................15182
2 Function - Basic audio playback.................................................................................................................................................................................................................................................................................................................................................................................................................................15184
2.1 General notes, components used............................................................................................................................................................................................................................................................................................................................................................................................................................15184
2.2 Description of audio playback function....................................................................................................................................................................................................................................................................................................................................................................................................................15184
3 Function - Sound settings.......................................................................................................................................................................................................................................................................................................................................................................................................................................15185
3.1 General notes, components used............................................................................................................................................................................................................................................................................................................................................................................................................................15185
3.2 Description of fader function.............................................................................................................................................................................................................................................................................................................................................................................................................................15185
3.3 Description of balance function...........................................................................................................................................................................................................................................................................................................................................................................................................................15186
3.4 Description of position-dependent volume correction / time correction.....................................................................................................................................................................................................................................................................................................................................................................................15186
3.5 Description of frequency response correction..............................................................................................................................................................................................................................................................................................................................................................................................................15188
3.6 Description of automatic source volume correction.........................................................................................................................................................................................................................................................................................................................................................................................................15188
3.7 Description of Audio during route guidance................................................................................................................................................................................................................................................................................................................................................................................................................15189
3.8 Description of surround level function....................................................................................................................................................................................................................................................................................................................................................................................................................15190
3.9 Notes for service.........................................................................................................................................................................................................................................................................................................................................................................................................................................15191
4 Function - adaptive volume control..............................................................................................................................................................................................................................................................................................................................................................................................................................15192
4.1 General notes, components used............................................................................................................................................................................................................................................................................................................................................................................................................................15192
4.2 Description of GALA function..............................................................................................................................................................................................................................................................................................................................................................................................................................15192
4.3 Description of dynamic noise compensation.................................................................................................................................................................................................................................................................................................................................................................................................................15192
System_description_-_infotainment_and_navigation_system...................................................................................................................................................................................................................................................................................................................................................................................................................15194
01 – Self-diagnosis, electrical checks................................................................................................................................................................................................................................................................................................................................................................................................................................15198
1 General information on navigation system........................................................................................................................................................................................................................................................................................................................................................................................................................15198
1.1 Definition of terms.......................................................................................................................................................................................................................................................................................................................................................................................................................................15199
1.2 Technical data............................................................................................................................................................................................................................................................................................................................................................................................................................................15199
1.3 Components used in MMI high (2nd generation)..............................................................................................................................................................................................................................................................................................................................................................................................................15200
1.4 Components used in MMI basic (2nd generation).............................................................................................................................................................................................................................................................................................................................................................................................................15201
1.5 Components used in MMI (3rd generation)...................................................................................................................................................................................................................................................................................................................................................................................................................15202
2 Function - Satellite navigation.................................................................................................................................................................................................................................................................................................................................................................................................................................15204
2.1 General notes, components used............................................................................................................................................................................................................................................................................................................................................................................................................................15204
2.2 Description...............................................................................................................................................................................................................................................................................................................................................................................................................................................15204
2.3 Notes for service.........................................................................................................................................................................................................................................................................................................................................................................................................................................15204
3 Function - Dead reckoning navigation............................................................................................................................................................................................................................................................................................................................................................................................................................15205
3.1 General notes, components used............................................................................................................................................................................................................................................................................................................................................................................................................................15205
3.2 Description...............................................................................................................................................................................................................................................................................................................................................................................................................................................15205
3.3 Notes for service.........................................................................................................................................................................................................................................................................................................................................................................................................................................15205
4 Function - Vehicle navigation...................................................................................................................................................................................................................................................................................................................................................................................................................................15206
4.1 General notes, components used............................................................................................................................................................................................................................................................................................................................................................................................................................15206
4.2 Description...............................................................................................................................................................................................................................................................................................................................................................................................................................................15206
4.3 Notes for service.........................................................................................................................................................................................................................................................................................................................................................................................................................................15207
System_description_-_interior_lights......................................................................................................................................................................................................................................................................................................................................................................................................................................15208
01 – Self-diagnosis, electrical checks................................................................................................................................................................................................................................................................................................................................................................................................................................15212
1 General notes on the interior light functions...................................................................................................................................................................................................................................................................................................................................................................................................................15212
1.1 General notes.............................................................................................................................................................................................................................................................................................................................................................................................................................................15212
1.2 Identifying the door contact states.......................................................................................................................................................................................................................................................................................................................................................................................................................15212
1.3 Identifying the states of the S-contact and the ignition..................................................................................................................................................................................................................................................................................................................................................................................................15213
1.4 Identifying the status of the exterior vehicle lighting...................................................................................................................................................................................................................................................................................................................................................................................................15214
1.5 Information for service...................................................................................................................................................................................................................................................................................................................................................................................................................................15215
2 Interior lighting, reading light, glove box light and vanity mirror light.......................................................................................................................................................................................................................................................................................................................................................................................15216
2.1 General notes.............................................................................................................................................................................................................................................................................................................................................................................................................................................15216
2.2 Interior lighting.........................................................................................................................................................................................................................................................................................................................................................................................................................................15217
2.2.1 Components used.....................................................................................................................................................................................................................................................................................................................................................................................................................................15217
2.2.2 Description.........................................................................................................................................................................................................................................................................................................................................................................................................................................15217
2.3 Reading light.............................................................................................................................................................................................................................................................................................................................................................................................................................................15218
2.3.1 Components used.....................................................................................................................................................................................................................................................................................................................................................................................................................................15218
2.3.2 Description.........................................................................................................................................................................................................................................................................................................................................................................................................................................15218
2.4 Glove box light...........................................................................................................................................................................................................................................................................................................................................................................................................................................15219
2.4.1 Components used.....................................................................................................................................................................................................................................................................................................................................................................................................................................15219
2.4.2 Description.........................................................................................................................................................................................................................................................................................................................................................................................................................................15219
2.5 Vanity mirror light.......................................................................................................................................................................................................................................................................................................................................................................................................................................15219
2.5.1 Components used.....................................................................................................................................................................................................................................................................................................................................................................................................................................15219
2.5.2 Description.........................................................................................................................................................................................................................................................................................................................................................................................................................................15219
2.6 Information for service...................................................................................................................................................................................................................................................................................................................................................................................................................................15219
3 Footwell lighting...............................................................................................................................................................................................................................................................................................................................................................................................................................................15220
3.1 Components used...........................................................................................................................................................................................................................................................................................................................................................................................................................................15220
3.2 Description...............................................................................................................................................................................................................................................................................................................................................................................................................................................15220
3.3 Information for service...................................................................................................................................................................................................................................................................................................................................................................................................................................15220
4 Luggage compartment light.......................................................................................................................................................................................................................................................................................................................................................................................................................................15221
4.1 Components used...........................................................................................................................................................................................................................................................................................................................................................................................................................................15221
4.2 Description...............................................................................................................................................................................................................................................................................................................................................................................................................................................15221
4.3 Information for service...................................................................................................................................................................................................................................................................................................................................................................................................................................15222
5 Button and display illumination.................................................................................................................................................................................................................................................................................................................................................................................................................................15223
5.1 General notes.............................................................................................................................................................................................................................................................................................................................................................................................................................................15223
5.2 Terminal 58s..............................................................................................................................................................................................................................................................................................................................................................................................................................................15223
5.2.1 Other components used...............................................................................................................................................................................................................................................................................................................................................................................................................................15223
5.2.2 Description.........................................................................................................................................................................................................................................................................................................................................................................................................................................15223
5.2.3 Information for service.............................................................................................................................................................................................................................................................................................................................................................................................................................15224
5.3 Terminal 58st.............................................................................................................................................................................................................................................................................................................................................................................................................................................15225
5.3.1 Other components used...............................................................................................................................................................................................................................................................................................................................................................................................................................15225
5.3.2 Description.........................................................................................................................................................................................................................................................................................................................................................................................................................................15225
5.3.3 Information for service.............................................................................................................................................................................................................................................................................................................................................................................................................................15225
5.4 Terminal 58d..............................................................................................................................................................................................................................................................................................................................................................................................................................................15225
5.4.1 Description.........................................................................................................................................................................................................................................................................................................................................................................................................................................15225
5.4.2 Information for service.............................................................................................................................................................................................................................................................................................................................................................................................................................15225
5.5 Illumination of hazard warning lights button -E229-.......................................................................................................................................................................................................................................................................................................................................................................................................15226
5.5.1 Other components used...............................................................................................................................................................................................................................................................................................................................................................................................................................15226
5.5.2 Description.........................................................................................................................................................................................................................................................................................................................................................................................................................................15226
5.5.3 Information for service.............................................................................................................................................................................................................................................................................................................................................................................................................................15227
System_description_-_lane_change_assist_(Audi_side_assist)................................................................................................................................................................................................................................................................................................................................................................................................................15228
01 – Self-diagnosis, electrical checks................................................................................................................................................................................................................................................................................................................................................................................................................................15232
1 General notes on lane change assist.............................................................................................................................................................................................................................................................................................................................................................................................................................15232
1.1 Definition of terms.......................................................................................................................................................................................................................................................................................................................................................................................................................................15232
1.2 Components used...........................................................................................................................................................................................................................................................................................................................................................................................................................................15232
1.3 Exchange of data between system components................................................................................................................................................................................................................................................................................................................................................................................................................15233
2 Description.....................................................................................................................................................................................................................................................................................................................................................................................................................................................15235
2.1 Conditions for activation/deactivation....................................................................................................................................................................................................................................................................................................................................................................................................................15235
2.2 System conditions for lane change assist function.........................................................................................................................................................................................................................................................................................................................................................................................................15235
2.3 System response to faults.................................................................................................................................................................................................................................................................................................................................................................................................................................15235
3 Notes for service...............................................................................................................................................................................................................................................................................................................................................................................................................................................15237
3.1 Lane change assist settings...............................................................................................................................................................................................................................................................................................................................................................................................................................15237
3.2 Special calibration tools.................................................................................................................................................................................................................................................................................................................................................................................................................................15237
3.3 When is it necessary to calibrate the system?.............................................................................................................................................................................................................................................................................................................................................................................................................15237
System_description_-_lane_departure_warning_(Audi_lane_assist)............................................................................................................................................................................................................................................................................................................................................................................................................15238
01 – Self-diagnosis, electrical checks................................................................................................................................................................................................................................................................................................................................................................................................................................15242
1 General notes on lane departure warning.........................................................................................................................................................................................................................................................................................................................................................................................................................15242
1.1 Technical data............................................................................................................................................................................................................................................................................................................................................................................................................................................15242
1.2 Components used...........................................................................................................................................................................................................................................................................................................................................................................................................................................15242
1.3 Exchange of data between system components................................................................................................................................................................................................................................................................................................................................................................................................................15243
2 Description.....................................................................................................................................................................................................................................................................................................................................................................................................................................................15245
2.1 Electronic image processing...............................................................................................................................................................................................................................................................................................................................................................................................................................15245
2.2 Switching the system on and off...........................................................................................................................................................................................................................................................................................................................................................................................................................15245
2.3 Possible states of warning lamp in instrument cluster.....................................................................................................................................................................................................................................................................................................................................................................................................15245
3 Notes for service...............................................................................................................................................................................................................................................................................................................................................................................................................................................15247
3.1 Calibration...............................................................................................................................................................................................................................................................................................................................................................................................................................................15247
3.1.1 Calibration principle...............................................................................................................................................................................................................................................................................................................................................................................................................................15247
3.1.2 New special calibration tool........................................................................................................................................................................................................................................................................................................................................................................................................................15247
3.1.3 Further tools required for calibration..............................................................................................................................................................................................................................................................................................................................................................................................................15248
3.1.4 When is it necessary to calibrate the system?.......................................................................................................................................................................................................................................................................................................................................................................................................15248
3.1.5 Calibration procedure...............................................................................................................................................................................................................................................................................................................................................................................................................................15249
3.1.6 Online calibration..................................................................................................................................................................................................................................................................................................................................................................................................................................15249
3.2 Diagnosis.................................................................................................................................................................................................................................................................................................................................................................................................................................................15249
3.2.1 Measured value blocks...............................................................................................................................................................................................................................................................................................................................................................................................................................15249
3.2.2 Final control diagnoses.............................................................................................................................................................................................................................................................................................................................................................................................................................15250
3.2.3 Control unit coding.................................................................................................................................................................................................................................................................................................................................................................................................................................15250
3.2.4 Basic setting.......................................................................................................................................................................................................................................................................................................................................................................................................................................15250
System_description_-_Running_gear__steering_wheel.........................................................................................................................................................................................................................................................................................................................................................................................................................15251
01 – Self-diagnosis, electrical checks................................................................................................................................................................................................................................................................................................................................................................................................................................15255
1 General notes on steering wheel.................................................................................................................................................................................................................................................................................................................................................................................................................................15255
2 Horns...........................................................................................................................................................................................................................................................................................................................................................................................................................................................15256
2.1 Components used...........................................................................................................................................................................................................................................................................................................................................................................................................................................15256
2.2 Description of operation..................................................................................................................................................................................................................................................................................................................................................................................................................................15256
3 Multi-function steering wheel...................................................................................................................................................................................................................................................................................................................................................................................................................................15257
3.1 General notes.............................................................................................................................................................................................................................................................................................................................................................................................................................................15257
3.2 Components used...........................................................................................................................................................................................................................................................................................................................................................................................................................................15257
3.3 Description of operation..................................................................................................................................................................................................................................................................................................................................................................................................................................15257
3.4 Example function: changing radio stations.................................................................................................................................................................................................................................................................................................................................................................................................................15259
3.5 Notes for service.........................................................................................................................................................................................................................................................................................................................................................................................................................................15260
System_description_-_Windows_and_doors....................................................................................................................................................................................................................................................................................................................................................................................................................................15261
01 – Self-diagnosis, electrical checks................................................................................................................................................................................................................................................................................................................................................................................................................................15265
1 Central locking, radio remote control...........................................................................................................................................................................................................................................................................................................................................................................................................................15265
1.1 General...................................................................................................................................................................................................................................................................................................................................................................................................................................................15265
1.2 Components involved.......................................................................................................................................................................................................................................................................................................................................................................................................................................15265
1.3 Central locking radio remote control function.............................................................................................................................................................................................................................................................................................................................................................................................................15266
1.3.1 General.............................................................................................................................................................................................................................................................................................................................................................................................................................................15266
1.3.2 Functionality onboard the vehicle...................................................................................................................................................................................................................................................................................................................................................................................................................15266
1.3.3 Functionality outside of the vehicle................................................................................................................................................................................................................................................................................................................................................................................................................15267
1.4 Notes for service.........................................................................................................................................................................................................................................................................................................................................................................................................................................15268
1.4.1 Coding..............................................................................................................................................................................................................................................................................................................................................................................................................................................15268
1.4.2 Service data in remote control key..................................................................................................................................................................................................................................................................................................................................................................................................................15268
2 Convenience opening/closing ....................................................................................................................................................................................................................................................................................................................................................................................................................................15269
2.1 General...................................................................................................................................................................................................................................................................................................................................................................................................................................................15269
2.2 Components involved.......................................................................................................................................................................................................................................................................................................................................................................................................................................15269
2.3 Convenience opening/closing function......................................................................................................................................................................................................................................................................................................................................................................................................................15270
2.3.1 General.............................................................................................................................................................................................................................................................................................................................................................................................................................................15270
2.3.2 Preconditions:......................................................................................................................................................................................................................................................................................................................................................................................................................................15270
2.3.3 Function description................................................................................................................................................................................................................................................................................................................................................................................................................................15270
2.3.4 Functional principle................................................................................................................................................................................................................................................................................................................................................................................................................................15271
2.4 Notes for service.........................................................................................................................................................................................................................................................................................................................................................................................................................................15272
2.4.1 Coding..............................................................................................................................................................................................................................................................................................................................................................................................................................................15272
2.4.2 General.............................................................................................................................................................................................................................................................................................................................................................................................................................................15272
3 Raising/lowering windows........................................................................................................................................................................................................................................................................................................................................................................................................................................15274
3.1 General...................................................................................................................................................................................................................................................................................................................................................................................................................................................15274
3.2 Components involved.......................................................................................................................................................................................................................................................................................................................................................................................................................................15274
3.3 Window lifter function....................................................................................................................................................................................................................................................................................................................................................................................................................................15274
3.3.1 General.............................................................................................................................................................................................................................................................................................................................................................................................................................................15274
3.3.2 Function description................................................................................................................................................................................................................................................................................................................................................................................................................................15275
3.4 Note for service..........................................................................................................................................................................................................................................................................................................................................................................................................................................15277
3.4.1 Coding..............................................................................................................................................................................................................................................................................................................................................................................................................................................15277
System_description_-_wiper_and_washer_systems.............................................................................................................................................................................................................................................................................................................................................................................................................................15278
01 – Self-diagnosis, electrical checks................................................................................................................................................................................................................................................................................................................................................................................................................................15282
1 General notes on wiper and washer systems.......................................................................................................................................................................................................................................................................................................................................................................................................................15282
1.1 General notes and technical data..........................................................................................................................................................................................................................................................................................................................................................................................................................15282
1.2 Components used...........................................................................................................................................................................................................................................................................................................................................................................................................................................15282
2 Windscreen wiping without rain sensor...........................................................................................................................................................................................................................................................................................................................................................................................................................15283
2.1 General notes and components used.........................................................................................................................................................................................................................................................................................................................................................................................................................15283
2.2 Description...............................................................................................................................................................................................................................................................................................................................................................................................................................................15283
2.3 Notes for service.........................................................................................................................................................................................................................................................................................................................................................................................................................................15283
3 Windscreen wiping with rain sensor..............................................................................................................................................................................................................................................................................................................................................................................................................................15284
3.1 General notes and components used.........................................................................................................................................................................................................................................................................................................................................................................................................................15284
3.2 Description...............................................................................................................................................................................................................................................................................................................................................................................................................................................15284
3.3 Notes for service.........................................................................................................................................................................................................................................................................................................................................................................................................................................15284
3.4 Notes on the windscreen...................................................................................................................................................................................................................................................................................................................................................................................................................................15284
4 Headlight washer system (HWS)...................................................................................................................................................................................................................................................................................................................................................................................................................................15286
4.1 General notes and components used.........................................................................................................................................................................................................................................................................................................................................................................................................................15286
4.2 Description...............................................................................................................................................................................................................................................................................................................................................................................................................................................15286
4.3 Notes for service.........................................................................................................................................................................................................................................................................................................................................................................................................................................15286
5 Windscreen washing..............................................................................................................................................................................................................................................................................................................................................................................................................................................15287
5.1 General notes and components used.........................................................................................................................................................................................................................................................................................................................................................................................................................15287
5.2 Description...............................................................................................................................................................................................................................................................................................................................................................................................................................................15287
5.3 Notes for service.........................................................................................................................................................................................................................................................................................................................................................................................................................................15287
6 Washer jet heating..............................................................................................................................................................................................................................................................................................................................................................................................................................................15288
TDI_injection_and_glow_plug_system_4-cyl__2_0_ltr__4-valve_common_rail__generation_II.....................................................................................................................................................................................................................................................................................................................................................................................15289
23 – Mixture preparation - injection..................................................................................................................................................................................................................................................................................................................................................................................................................................15293
1 Safety precautions and rules for cleanliness....................................................................................................................................................................................................................................................................................................................................................................................................................15293
1.1 Safety precautions when working on the injection and glow plug system.....................................................................................................................................................................................................................................................................................................................................................................................15293
1.2 Safety precautions when using testers and measuring instruments during a road test........................................................................................................................................................................................................................................................................................................................................................................15294
1.3 Safety precautions when working on vehicles with start/stop system........................................................................................................................................................................................................................................................................................................................................................................................15294
1.4 Safety precautions when working on the fuel system........................................................................................................................................................................................................................................................................................................................................................................................................15295
1.5 Rules for cleanliness and instructions for working on fuel system.........................................................................................................................................................................................................................................................................................................................................................................................15295
1.6 Checking vacuum system....................................................................................................................................................................................................................................................................................................................................................................................................................................15296
2 Overview of fitting locations - injection system................................................................................................................................................................................................................................................................................................................................................................................................................15298
3 Overview - fuel system..........................................................................................................................................................................................................................................................................................................................................................................................................................................15306
4 Filling and bleeding fuel system................................................................................................................................................................................................................................................................................................................................................................................................................................15308
5 Air cleaner.....................................................................................................................................................................................................................................................................................................................................................................................................................................................15309
5.1 Exploded view - air cleaner...............................................................................................................................................................................................................................................................................................................................................................................................................................15309
5.2 Removing and installing engine cover panel................................................................................................................................................................................................................................................................................................................................................................................................................15310
5.3 Removing and installing air filter element................................................................................................................................................................................................................................................................................................................................................................................................................15311
5.4 Removing and installing air cleaner (bottom section)......................................................................................................................................................................................................................................................................................................................................................................................................15312
5.5 Removing and installing air mass meter -G70-..............................................................................................................................................................................................................................................................................................................................................................................................................15314
6 Intake manifold.................................................................................................................................................................................................................................................................................................................................................................................................................................................15315
6.1 Exploded view - intake manifold...........................................................................................................................................................................................................................................................................................................................................................................................................................15315
6.2 Removing and installing throttle valve module -J338-......................................................................................................................................................................................................................................................................................................................................................................................................15316
6.3 Removing and installing intake manifold...................................................................................................................................................................................................................................................................................................................................................................................................................15316
7 High-pressure pump..............................................................................................................................................................................................................................................................................................................................................................................................................................................15320
7.1 Exploded view - high-pressure pump........................................................................................................................................................................................................................................................................................................................................................................................................................15320
7.2 Removing and installing high-pressure pump................................................................................................................................................................................................................................................................................................................................................................................................................15321
7.3 Performing first fuel filling after installing high-pressure pump.........................................................................................................................................................................................................................................................................................................................................................................................15324
7.4 Checking fuel system for leaks............................................................................................................................................................................................................................................................................................................................................................................................................................15325
8 Injectors.......................................................................................................................................................................................................................................................................................................................................................................................................................................................15326
8.1 Exploded view - injectors.................................................................................................................................................................................................................................................................................................................................................................................................................................15326
8.2 Checking injectors........................................................................................................................................................................................................................................................................................................................................................................................................................................15329
8.3 Performing adaption of correction values for injectors....................................................................................................................................................................................................................................................................................................................................................................................................15329
8.4 Checking return flow rate of injectors with engine running................................................................................................................................................................................................................................................................................................................................................................................................15330
8.5 Checking return flow rate of injectors at starter cranking speed..........................................................................................................................................................................................................................................................................................................................................................................................15332
8.6 Checking for injectors sticking open......................................................................................................................................................................................................................................................................................................................................................................................................................15334
8.7 Removing and installing injectors.........................................................................................................................................................................................................................................................................................................................................................................................................................15335
8.8 Renewing injector seals...................................................................................................................................................................................................................................................................................................................................................................................................................................15341
9 Senders and sensors.............................................................................................................................................................................................................................................................................................................................................................................................................................................15343
9.1 Removing and installing fuel rail.........................................................................................................................................................................................................................................................................................................................................................................................................................15343
9.2 Installing high-pressure pipes............................................................................................................................................................................................................................................................................................................................................................................................................................15345
9.3 Checking fuel pressure (low pressure).....................................................................................................................................................................................................................................................................................................................................................................................................................15346
9.4 Checking fuel pressure regulating valve -N276-............................................................................................................................................................................................................................................................................................................................................................................................................15348
9.5 Removing and installing fuel pressure regulating valve -N276-.............................................................................................................................................................................................................................................................................................................................................................................................15350
9.6 Removing and installing fuel pressure sender -G247-.......................................................................................................................................................................................................................................................................................................................................................................................................15351
10 Lambda probe...................................................................................................................................................................................................................................................................................................................................................................................................................................................15355
10.1 Exploded view - Lambda probe and exhaust gas temperature senders.........................................................................................................................................................................................................................................................................................................................................................................................15355
10.2 Removing and installing Lambda probe -G39- with Lambda probe heater -Z19-................................................................................................................................................................................................................................................................................................................................................................................15356
10.3 Removing and installing pressure differential sender -G505-..............................................................................................................................................................................................................................................................................................................................................................................................15357
11 Engine control unit............................................................................................................................................................................................................................................................................................................................................................................................................................................15358
11.1 Wiring and component check with test box -V.A.G 1598/42-.................................................................................................................................................................................................................................................................................................................................................................................................15358
11.2 Removing and installing engine control unit -J623-.......................................................................................................................................................................................................................................................................................................................................................................................................15359
28 – Glow plug system.................................................................................................................................................................................................................................................................................................................................................................................................................................................15363
1 Glow plug system................................................................................................................................................................................................................................................................................................................................................................................................................................................15363
1.1 Checking glow plug system.................................................................................................................................................................................................................................................................................................................................................................................................................................15363
1.2 Exploded view - glow plugs, Hall sender, engine speed sender..............................................................................................................................................................................................................................................................................................................................................................................................15363
1.3 Removing and installing glow plugs........................................................................................................................................................................................................................................................................................................................................................................................................................15364
1.4 Removing and installing Hall sender -G40-.................................................................................................................................................................................................................................................................................................................................................................................................................15366
1.5 Removing and installing engine speed sender -G28-.........................................................................................................................................................................................................................................................................................................................................................................................................15367
TDI_injection_and_glow_plug_system_4-cyl_2_0_ltr_4-valve_common_rail......................................................................................................................................................................................................................................................................................................................................................................................................15368
23 – Mixture preparation - injection..................................................................................................................................................................................................................................................................................................................................................................................................................................15372
1 Safety precautions and rules for cleanliness....................................................................................................................................................................................................................................................................................................................................................................................................................15372
1.1 Safety precautions when using testers and measuring instruments during a road test........................................................................................................................................................................................................................................................................................................................................................................15372
1.2 Safety precautions for vehicles with start/stop system....................................................................................................................................................................................................................................................................................................................................................................................................15373
1.3 Safety precautions when working on the fuel system........................................................................................................................................................................................................................................................................................................................................................................................................15373
1.4 To avoid any risk of injuries to persons and/or damage to the injection and glow plug system, always observe the following safety precautions:............................................................................................................................................................................................................................................................................................................15374
1.5 Checking vacuum system....................................................................................................................................................................................................................................................................................................................................................................................................................................15375
2 Overview of fitting locations...................................................................................................................................................................................................................................................................................................................................................................................................................................15376
3 System layout...................................................................................................................................................................................................................................................................................................................................................................................................................................................15384
4 Fuel system - exploded view.....................................................................................................................................................................................................................................................................................................................................................................................................................................15386
5 Bleeding fuel system............................................................................................................................................................................................................................................................................................................................................................................................................................................15389
6 Air cleaner.....................................................................................................................................................................................................................................................................................................................................................................................................................................................15390
6.1 Air cleaner - exploded view...............................................................................................................................................................................................................................................................................................................................................................................................................................15390
6.2 Removing and installing engine cover panel................................................................................................................................................................................................................................................................................................................................................................................................................15391
6.3 Removing and installing air filter element................................................................................................................................................................................................................................................................................................................................................................................................................15391
6.4 Removing air cleaner (bottom section).....................................................................................................................................................................................................................................................................................................................................................................................................................15392
7 Intake manifold.................................................................................................................................................................................................................................................................................................................................................................................................................................................15395
7.1 Intake manifold - exploded view...........................................................................................................................................................................................................................................................................................................................................................................................................................15395
7.2 Removing and installing intake manifold...................................................................................................................................................................................................................................................................................................................................................................................................................15395
7.3 Removing and installing fuel rail.........................................................................................................................................................................................................................................................................................................................................................................................................................15399
8 High-pressure pump..............................................................................................................................................................................................................................................................................................................................................................................................................................................15402
8.1 Removing and installing high-pressure pump................................................................................................................................................................................................................................................................................................................................................................................................................15402
8.2 Performing first fuel filling operation after installing high-pressure pump...............................................................................................................................................................................................................................................................................................................................................................................15403
9 Injectors.......................................................................................................................................................................................................................................................................................................................................................................................................................................................15405
9.1 Checking injectors........................................................................................................................................................................................................................................................................................................................................................................................................................................15405
9.2 Performing adaption of injectors..........................................................................................................................................................................................................................................................................................................................................................................................................................15405
9.3 Checking return flow rate of injectors with engine running................................................................................................................................................................................................................................................................................................................................................................................................15406
9.4 Checking return flow rate of injectors at starter cranking speed..........................................................................................................................................................................................................................................................................................................................................................................................15408
9.5 Checking for injectors sticking open......................................................................................................................................................................................................................................................................................................................................................................................................................15410
9.6 Removing and installing injectors.........................................................................................................................................................................................................................................................................................................................................................................................................................15412
10 Components of injection system.................................................................................................................................................................................................................................................................................................................................................................................................................................15419
10.1 Removing and installing air mass meter -G70-.............................................................................................................................................................................................................................................................................................................................................................................................................15419
10.2 Installing high-pressure pipes...........................................................................................................................................................................................................................................................................................................................................................................................................................15420
10.3 Checking pressure retention valve in fuel return line....................................................................................................................................................................................................................................................................................................................................................................................................15422
10.4 Checking fuel system for leaks...........................................................................................................................................................................................................................................................................................................................................................................................................................15423
10.5 Checking fuel pressure (low pressure) system.............................................................................................................................................................................................................................................................................................................................................................................................................15423
10.6 Checking fuel pressure regulating valve -N276-...........................................................................................................................................................................................................................................................................................................................................................................................................15425
10.7 Removing and installing fuel pressure regulating valve -N276-............................................................................................................................................................................................................................................................................................................................................................................................15426
10.8 Removing and installing fuel pressure sender -G247-......................................................................................................................................................................................................................................................................................................................................................................................................15428
11 Lambda probes..................................................................................................................................................................................................................................................................................................................................................................................................................................................15432
11.1 Lambda probe - exploded view.............................................................................................................................................................................................................................................................................................................................................................................................................................15432
11.2 Removing and installing Lambda probe -G39- with Lambda probe heater -Z19-................................................................................................................................................................................................................................................................................................................................................................................15433
11.3 Removing and installing exhaust gas pressure sensor 1 -G450-.............................................................................................................................................................................................................................................................................................................................................................................................15434
12 Engine control unit............................................................................................................................................................................................................................................................................................................................................................................................................................................15435
12.1 Wiring and component check with test box -V.A.G 1598/42-.................................................................................................................................................................................................................................................................................................................................................................................................15435
12.2 Renewing engine control unit -J623-......................................................................................................................................................................................................................................................................................................................................................................................................................15436
28 – Glow plug system.................................................................................................................................................................................................................................................................................................................................................................................................................................................15440
1 Checking glow plug system.......................................................................................................................................................................................................................................................................................................................................................................................................................................15440
1.1 Removing and installing glow plugs........................................................................................................................................................................................................................................................................................................................................................................................................................15440
1.2 Removing and installing engine speed sender -G28-.........................................................................................................................................................................................................................................................................................................................................................................................................15442
1.3 Removing and installing Hall sender -G40-.................................................................................................................................................................................................................................................................................................................................................................................................................15443
TDI_injection_and_glow_plug_system_6-cyl__2_7_3_0ltr__4-valve_common_rail.................................................................................................................................................................................................................................................................................................................................................................................................15445
23 – Mixture preparation - injection..................................................................................................................................................................................................................................................................................................................................................................................................................................15449
1 Safety precautions and rules for cleanliness....................................................................................................................................................................................................................................................................................................................................................................................................................15449
1.1 General note for vehicles with SCR system.................................................................................................................................................................................................................................................................................................................................................................................................................15449
1.2 Adapting learnt value after draining reducing agent or renewing components................................................................................................................................................................................................................................................................................................................................................................................15449
1.3 Safety precautions when using testers and measuring instruments during a road test........................................................................................................................................................................................................................................................................................................................................................................15450
1.4 Safety precautions for vehicles with start/stop system....................................................................................................................................................................................................................................................................................................................................................................................................15450
1.5 Safety precautions when working on the fuel system........................................................................................................................................................................................................................................................................................................................................................................................................15451
1.6 Safety precautions when working on the injection and glow plug system.....................................................................................................................................................................................................................................................................................................................................................................................15453
1.7 Checking vacuum system....................................................................................................................................................................................................................................................................................................................................................................................................................................15453
2 Overview of fitting locations (CAPA, CAMA, CAMB, CCWA, CCWB, CGKA, CGKB)........................................................................................................................................................................................................................................................................................................................................................................................15455
3 Overview of fitting locations (CCLA)............................................................................................................................................................................................................................................................................................................................................................................................................................15465
4 Fuel system - overview..........................................................................................................................................................................................................................................................................................................................................................................................................................................15475
5 Exploded view - fuel system (CAMA, CAMB, CCWA, CCWB, CGKA, CGKB, CCLA)..........................................................................................................................................................................................................................................................................................................................................................................................15478
6 Exploded view - fuel system (CAPA)..............................................................................................................................................................................................................................................................................................................................................................................................................................15482
7 Bleeding fuel system (CAMA, CAMB, CCWA, CCWB, CGKA, CGKB, CCLA).................................................................................................................................................................................................................................................................................................................................................................................................15485
8 Air cleaner.....................................................................................................................................................................................................................................................................................................................................................................................................................................................15486
8.1 Exploded view - air cleaner...............................................................................................................................................................................................................................................................................................................................................................................................................................15486
8.2 Removing and installing engine cover panel................................................................................................................................................................................................................................................................................................................................................................................................................15488
8.3 Removing and installing air filter element................................................................................................................................................................................................................................................................................................................................................................................................................15488
8.4 Removing air cleaner (bottom section).....................................................................................................................................................................................................................................................................................................................................................................................................................15490
9 Intake manifold.................................................................................................................................................................................................................................................................................................................................................................................................................................................15492
9.1 Exploded view - intake manifold...........................................................................................................................................................................................................................................................................................................................................................................................................................15492
9.2 Removing and installing intake manifold (top section).....................................................................................................................................................................................................................................................................................................................................................................................................15493
9.3 Removing and installing intake manifold (bottom section, left-side).......................................................................................................................................................................................................................................................................................................................................................................................15495
9.4 Removing and installing intake manifold (bottom section, right-side)......................................................................................................................................................................................................................................................................................................................................................................................15497
10 Toothed belt (CAMA, CAMB, CCWA, CCWB, CGKA, CGKB, CCLA)........................................................................................................................................................................................................................................................................................................................................................................................................15501
10.1 Exploded view - toothed belt for high-pressure pump......................................................................................................................................................................................................................................................................................................................................................................................................15501
10.2 Removing and installing toothed belt for high-pressure pump..............................................................................................................................................................................................................................................................................................................................................................................................15503
11 Toothed belt (CAPA)............................................................................................................................................................................................................................................................................................................................................................................................................................................15512
11.1 Exploded view - toothed belt for high-pressure pump......................................................................................................................................................................................................................................................................................................................................................................................................15512
11.2 Removing and installing toothed belt for high-pressure pump..............................................................................................................................................................................................................................................................................................................................................................................................15512
12 High-pressure pump (CAMA, CAMB, CCWA, CCWB, CGKA, CGKB, CCLA)..................................................................................................................................................................................................................................................................................................................................................................................................15517
12.1 Exploded view - high-pressure pump.......................................................................................................................................................................................................................................................................................................................................................................................................................15517
12.2 Removing and installing high-pressure pump...............................................................................................................................................................................................................................................................................................................................................................................................................15520
12.3 Performing first fuel filling after installing high-pressure pump (CAMA, CAMB, CCWA, CCWB, CGKA, CGKB, CCLA).............................................................................................................................................................................................................................................................................................................................................15522
13 High-pressure pump (CAPA)......................................................................................................................................................................................................................................................................................................................................................................................................................................15524
13.1 Exploded view - high-pressure pump.......................................................................................................................................................................................................................................................................................................................................................................................................................15524
13.2 Removing and installing high-pressure pump...............................................................................................................................................................................................................................................................................................................................................................................................................15525
13.3 Bleeding fuel system and checking for leaks..............................................................................................................................................................................................................................................................................................................................................................................................................15527
14 Injectors......................................................................................................................................................................................................................................................................................................................................................................................................................................................15529
14.1 Checking injectors.......................................................................................................................................................................................................................................................................................................................................................................................................................................15529
14.2 Performing adaption of correction values for injectors...................................................................................................................................................................................................................................................................................................................................................................................................15529
14.3 Checking return flow rate of injectors with engine running...............................................................................................................................................................................................................................................................................................................................................................................................15530
14.4 Checking return flow rate of injectors at starter cranking speed.........................................................................................................................................................................................................................................................................................................................................................................................15532
14.5 Checking for injectors sticking open.....................................................................................................................................................................................................................................................................................................................................................................................................................15534
14.6 Checking pressure retention valve in fuel return line....................................................................................................................................................................................................................................................................................................................................................................................................15536
14.7 Checking restrictor in fuel return line..................................................................................................................................................................................................................................................................................................................................................................................................................15537
14.8 Removing and installing injectors........................................................................................................................................................................................................................................................................................................................................................................................................................15538
15 Senders and sensors............................................................................................................................................................................................................................................................................................................................................................................................................................................15545
15.1 Removing and installing air mass meter -G70-.............................................................................................................................................................................................................................................................................................................................................................................................................15545
15.2 Installing high-pressure pipes...........................................................................................................................................................................................................................................................................................................................................................................................................................15545
15.3 Checking fuel pressure regulating valve -N276-...........................................................................................................................................................................................................................................................................................................................................................................................................15548
15.4 Removing and installing fuel pressure regulating valve -N276-............................................................................................................................................................................................................................................................................................................................................................................................15548
15.5 Removing and installing fuel pressure sender -G247-......................................................................................................................................................................................................................................................................................................................................................................................................15550
16 Lambda probe and exhaust gas temperature control (CAMA, CAMB, CCWA, CCWB, CGKA, CGKB, CAPA)....................................................................................................................................................................................................................................................................................................................................................................15553
16.1 Exploded view - Lambda probe and exhaust gas temperature control.........................................................................................................................................................................................................................................................................................................................................................................................15553
16.2 Removing and installing Lambda probe -G39- with Lambda probe heater -Z19-................................................................................................................................................................................................................................................................................................................................................................................15554
16.3 Removing and installing exhaust gas pressure sensor 1 -G450-.............................................................................................................................................................................................................................................................................................................................................................................................15555
17 Lambda probe and exhaust gas temperature control (CCLA)........................................................................................................................................................................................................................................................................................................................................................................................................15556
17.1 Exploded view - Lambda probe and exhaust gas temperature control.........................................................................................................................................................................................................................................................................................................................................................................................15556
17.2 Removing and installing Lambda probe -G39- with Lambda probe heater -Z19-................................................................................................................................................................................................................................................................................................................................................................................15557
17.3 Removing and installing control unit for NOx sender -J583- with NOx sender -G295-........................................................................................................................................................................................................................................................................................................................................................................15558
17.4 Removing and installing control unit for NOx sender 2 -J881- with NOx sender 2 -G687-....................................................................................................................................................................................................................................................................................................................................................................15559
17.5 Removing and installing pressure differential sender -G505-..............................................................................................................................................................................................................................................................................................................................................................................................15559
18 Engine control unit............................................................................................................................................................................................................................................................................................................................................................................................................................................15561
18.1 Wiring and component check with test box -V.A.G 1598/42-.................................................................................................................................................................................................................................................................................................................................................................................................15561
18.2 Renewing engine control unit -J623-......................................................................................................................................................................................................................................................................................................................................................................................................................15563
28 – Glow plug system.................................................................................................................................................................................................................................................................................................................................................................................................................................................15567
1 Removing and installing glow plugs (CAMA, CAPA, CAMB, CCWA, CCWB, CGKA, CGKB)...................................................................................................................................................................................................................................................................................................................................................................................15567
2 Removing and installing glow plugs (CCLA).......................................................................................................................................................................................................................................................................................................................................................................................................................15569
3 Removing and installing engine speed sender -G28-...............................................................................................................................................................................................................................................................................................................................................................................................................15571
TDI_injection_and_glow_plug_system_6-cyl__3_0_ltr__4-valve_common_rail__generation_II.....................................................................................................................................................................................................................................................................................................................................................................................15572
23 – Mixture preparation - injection..................................................................................................................................................................................................................................................................................................................................................................................................................................15576
1 Safety precautions and rules for cleanliness....................................................................................................................................................................................................................................................................................................................................................................................................................15576
1.1 Safety precautions when using testers and measuring instruments during a road test........................................................................................................................................................................................................................................................................................................................................................................15576
1.2 Safety precautions when working on vehicles with start/stop system........................................................................................................................................................................................................................................................................................................................................................................................15577
1.3 Safety precautions when working on the fuel system........................................................................................................................................................................................................................................................................................................................................................................................................15577
1.4 Safety precautions when working on the injection and glow plug system.....................................................................................................................................................................................................................................................................................................................................................................................15579
1.5 Checking vacuum system....................................................................................................................................................................................................................................................................................................................................................................................................................................15579
2 Injection system................................................................................................................................................................................................................................................................................................................................................................................................................................................15581
2.1 Overview of fitting locations - injection system..........................................................................................................................................................................................................................................................................................................................................................................................................15581
2.2 Overview - fuel system....................................................................................................................................................................................................................................................................................................................................................................................................................................15590
2.3 Filling and bleeding fuel system..........................................................................................................................................................................................................................................................................................................................................................................................................................15591
2.4 Vacuum system.............................................................................................................................................................................................................................................................................................................................................................................................................................................15592
3 Air cleaner.....................................................................................................................................................................................................................................................................................................................................................................................................................................................15593
3.1 Exploded view - air cleaner...............................................................................................................................................................................................................................................................................................................................................................................................................................15593
3.2 Removing and installing engine cover panel................................................................................................................................................................................................................................................................................................................................................................................................................15595
3.3 Removing and installing air filter element................................................................................................................................................................................................................................................................................................................................................................................................................15595
3.4 Removing and installing air cleaner housing...............................................................................................................................................................................................................................................................................................................................................................................................................15597
4 Intake manifold.................................................................................................................................................................................................................................................................................................................................................................................................................................................15599
4.1 Exploded view - intake manifold...........................................................................................................................................................................................................................................................................................................................................................................................................................15599
4.2 Removing and installing intake manifold...................................................................................................................................................................................................................................................................................................................................................................................................................15600
4.3 Removing and installing throttle valve module -J338-......................................................................................................................................................................................................................................................................................................................................................................................................15605
4.4 Removing and installing intake manifold flap motor -V157-.................................................................................................................................................................................................................................................................................................................................................................................................15606
5 High-pressure pump..............................................................................................................................................................................................................................................................................................................................................................................................................................................15608
5.1 Exploded view - high-pressure pump........................................................................................................................................................................................................................................................................................................................................................................................................................15608
5.2 Removing and installing high-pressure pump................................................................................................................................................................................................................................................................................................................................................................................................................15609
5.3 Performing first fuel filling after installing high-pressure pump.........................................................................................................................................................................................................................................................................................................................................................................................15614
6 Injectors.......................................................................................................................................................................................................................................................................................................................................................................................................................................................15616
6.1 Exploded view - injectors.................................................................................................................................................................................................................................................................................................................................................................................................................................15616
6.2 Checking injectors........................................................................................................................................................................................................................................................................................................................................................................................................................................15620
6.3 Performing adaption of correction values for injectors....................................................................................................................................................................................................................................................................................................................................................................................................15620
6.4 Checking return flow rate of injectors with engine running................................................................................................................................................................................................................................................................................................................................................................................................15621
6.5 Checking return flow rate of injectors at starter cranking speed..........................................................................................................................................................................................................................................................................................................................................................................................15625
6.6 Checking for injectors sticking open......................................................................................................................................................................................................................................................................................................................................................................................................................15627
6.7 Checking restrictor in fuel return line...................................................................................................................................................................................................................................................................................................................................................................................................................15629
6.8 Removing and installing injectors.........................................................................................................................................................................................................................................................................................................................................................................................................................15630
6.9 Removing and installing fuel rail.........................................................................................................................................................................................................................................................................................................................................................................................................................15635
6.10 Installing high-pressure pipes...........................................................................................................................................................................................................................................................................................................................................................................................................................15639
7 Senders and sensors.............................................................................................................................................................................................................................................................................................................................................................................................................................................15641
7.1 Removing and installing air mass meter -G70-..............................................................................................................................................................................................................................................................................................................................................................................................................15641
7.2 Checking fuel pressure regulating valve -N276-............................................................................................................................................................................................................................................................................................................................................................................................................15642
7.3 Removing and installing fuel pressure regulating valve -N276-.............................................................................................................................................................................................................................................................................................................................................................................................15643
7.4 Removing and installing fuel pressure sender -G247-.......................................................................................................................................................................................................................................................................................................................................................................................................15645
7.5 Removing and installing pressure differential sender -G505-...............................................................................................................................................................................................................................................................................................................................................................................................15648
8 Lambda probes and exhaust gas temperature senders...............................................................................................................................................................................................................................................................................................................................................................................................................15649
8.1 Exploded view - Lambda probe, exhaust gas temperature senders and pressure sender.........................................................................................................................................................................................................................................................................................................................................................................15649
8.2 Removing and installing Lambda probe -G39- with Lambda probe heater -Z19-.................................................................................................................................................................................................................................................................................................................................................................................15650
9 Engine control unit.............................................................................................................................................................................................................................................................................................................................................................................................................................................15652
9.1 Wiring and component check with isolator box -VAS 6606-...................................................................................................................................................................................................................................................................................................................................................................................................15652
9.2 Removing and installing engine control unit -J623-........................................................................................................................................................................................................................................................................................................................................................................................................15653
28 – Glow plug system.................................................................................................................................................................................................................................................................................................................................................................................................................................................15655
1 Glow plug system................................................................................................................................................................................................................................................................................................................................................................................................................................................15655
1.1 Checking glow plug system.................................................................................................................................................................................................................................................................................................................................................................................................................................15655
1.2 Exploded view - glow plugs, Hall sender, engine speed sender..............................................................................................................................................................................................................................................................................................................................................................................................15655
1.3 Removing and installing glow plugs........................................................................................................................................................................................................................................................................................................................................................................................................................15656
1.4 Removing and installing engine speed sender -G28-.........................................................................................................................................................................................................................................................................................................................................................................................................15658
1.5 Removing and installing Hall sender -G40-.................................................................................................................................................................................................................................................................................................................................................................................................................15658
Technical_data_for_diesel_engines.........................................................................................................................................................................................................................................................................................................................................................................................................................................15659
00 – Technical data...................................................................................................................................................................................................................................................................................................................................................................................................................................................15663
1 Overview of engines.............................................................................................................................................................................................................................................................................................................................................................................................................................................15663
1.1 Overview of engines with adjustment values (oil gauge tester T40178)......................................................................................................................................................................................................................................................................................................................................................................................15663
1.1.1 Audi A5 - vehicle model code 8T.....................................................................................................................................................................................................................................................................................................................................................................................................................15663
Technical_data_for_petrol_engines.........................................................................................................................................................................................................................................................................................................................................................................................................................................15666
00 – Technical data...................................................................................................................................................................................................................................................................................................................................................................................................................................................15670
1 Overview of engines.............................................................................................................................................................................................................................................................................................................................................................................................................................................15670
1.1 Overview of engines with adjustment values (oil gauge tester T40178)......................................................................................................................................................................................................................................................................................................................................................................................15670
1.1.1 Audi A5 - vehicle model code 8T.....................................................................................................................................................................................................................................................................................................................................................................................................................15670
Trailer_Operation_Guide...................................................................................................................................................................................................................................................................................................................................................................................................................................................15672
44 – Wheels, tyres, vehicle geometry..................................................................................................................................................................................................................................................................................................................................................................................................................................15676
1 Trailer Weight Guide............................................................................................................................................................................................................................................................................................................................................................................................................................................15676
1.1 General information on retrofitting a towing bracket......................................................................................................................................................................................................................................................................................................................................................................................................15676
1.2 Trailer Weight Guide - overview of models.................................................................................................................................................................................................................................................................................................................................................................................................................15676
2 Trailer weight - A1, type 8X....................................................................................................................................................................................................................................................................................................................................................................................................................................15678
2.1 Notes on maximum speed with trailer.......................................................................................................................................................................................................................................................................................................................................................................................................................15678
2.2 Petrol engine 2011 - 2015.................................................................................................................................................................................................................................................................................................................................................................................................................................15678
2.3 Diesel engine 2011 - 2015.................................................................................................................................................................................................................................................................................................................................................................................................................................15678
3 Trailer weight - A3, type 8P....................................................................................................................................................................................................................................................................................................................................................................................................................................15680
3.1 Petrol engine.............................................................................................................................................................................................................................................................................................................................................................................................................................................15680
3.2 Diesel engine.............................................................................................................................................................................................................................................................................................................................................................................................................................................15685
4 Trailer weight - A3 Cabriolet, type 8P..........................................................................................................................................................................................................................................................................................................................................................................................................................15690
4.1 Petrol engine.............................................................................................................................................................................................................................................................................................................................................................................................................................................15690
4.2 Diesel engine.............................................................................................................................................................................................................................................................................................................................................................................................................................................15690
5 Trailer weight - A3, type 8V....................................................................................................................................................................................................................................................................................................................................................................................................................................15692
5.1 77 kW petrol engine.......................................................................................................................................................................................................................................................................................................................................................................................................................................15692
5.2 81 kW, 1.2 ltr. TFSI petrol engine........................................................................................................................................................................................................................................................................................................................................................................................................................15693
5.3 90 kW petrol engine.......................................................................................................................................................................................................................................................................................................................................................................................................................................15693
5.4 92 kW, 1.4 ltr. TFSI petrol engine........................................................................................................................................................................................................................................................................................................................................................................................................................15693
5.5 103 kW petrol engine......................................................................................................................................................................................................................................................................................................................................................................................................................................15693
5.6 110 kW, 1.4 ltr. TFSI petrol engine.......................................................................................................................................................................................................................................................................................................................................................................................................................15693
5.7 132 kW petrol engine, front-wheel drive...................................................................................................................................................................................................................................................................................................................................................................................................................15694
5.8 132 kW petrol engine, quattro.............................................................................................................................................................................................................................................................................................................................................................................................................................15694
5.9 206 / 221 kW petrol engine, quattro.......................................................................................................................................................................................................................................................................................................................................................................................................................15694
5.10 77 kW diesel engine......................................................................................................................................................................................................................................................................................................................................................................................................................................15695
5.11 1.6 ltr. TDI engine - 81 kW, engine code DBKA............................................................................................................................................................................................................................................................................................................................................................................................................15695
5.12 1.6 ltr. TDI engine - 81 kW, engine code CXXB, front-wheel drive.........................................................................................................................................................................................................................................................................................................................................................................................15695
5.13 1.6 ltr. TDI engine - 81 kW, engine code CXXB, quattro...................................................................................................................................................................................................................................................................................................................................................................................................15696
5.14 2.0 ltr. TDI engine - 100 kW.............................................................................................................................................................................................................................................................................................................................................................................................................................15696
5.15 2.0 ltr. TDI engine - 110 kW, front-wheel drive..........................................................................................................................................................................................................................................................................................................................................................................................................15696
5.16 2.0 ltr. TDI engine - 110 kW, quattro....................................................................................................................................................................................................................................................................................................................................................................................................................15697
5.17 2.0 ltr. TDI engine - 135 kW, front-wheel drive..........................................................................................................................................................................................................................................................................................................................................................................................................15697
5.18 2.0 ltr. TDI engine - 135 kW, quattro....................................................................................................................................................................................................................................................................................................................................................................................................................15697
6 Trailer weight - A4 allroad, type 8K............................................................................................................................................................................................................................................................................................................................................................................................................................15698
6.1 Petrol engines - model years 2009 - 2015..................................................................................................................................................................................................................................................................................................................................................................................................................15698
6.2 Diesel engines - model years 2009 - 2015..................................................................................................................................................................................................................................................................................................................................................................................................................15698
7 Trailer weight - A4, type 8K....................................................................................................................................................................................................................................................................................................................................................................................................................................15699
7.1 Petrol engine.............................................................................................................................................................................................................................................................................................................................................................................................................................................15699
7.2 Diesel engine.............................................................................................................................................................................................................................................................................................................................................................................................................................................15700
8 Trailer weight - A4 Cabriolet, type 8H..........................................................................................................................................................................................................................................................................................................................................................................................................................15703
8.1 Petrol engine.............................................................................................................................................................................................................................................................................................................................................................................................................................................15703
8.2 Diesel engine.............................................................................................................................................................................................................................................................................................................................................................................................................................................15704
9 Trailer weight - A5 Coupé, type 8T..............................................................................................................................................................................................................................................................................................................................................................................................................................15705
9.1 Petrol engine.............................................................................................................................................................................................................................................................................................................................................................................................................................................15705
9.2 Diesel engine.............................................................................................................................................................................................................................................................................................................................................................................................................................................15706
10 Trailer weight - A5 Sportback, type 8T.........................................................................................................................................................................................................................................................................................................................................................................................................................15708
10.1 Petrol engine............................................................................................................................................................................................................................................................................................................................................................................................................................................15708
10.2 Diesel engine............................................................................................................................................................................................................................................................................................................................................................................................................................................15708
11 Trailer weight - A5 Cabriolet, type 8F.........................................................................................................................................................................................................................................................................................................................................................................................................................15710
11.1 Petrol engine............................................................................................................................................................................................................................................................................................................................................................................................................................................15710
11.2 Diesel engine............................................................................................................................................................................................................................................................................................................................................................................................................................................15710
12 Trailer weight - A6, type 4F...................................................................................................................................................................................................................................................................................................................................................................................................................................15712
12.1 Petrol engine............................................................................................................................................................................................................................................................................................................................................................................................................................................15712
12.2 Diesel engine............................................................................................................................................................................................................................................................................................................................................................................................................................................15714
13 Trailer weight - A6, type 4G...................................................................................................................................................................................................................................................................................................................................................................................................................................15717
13.1 Petrol engine............................................................................................................................................................................................................................................................................................................................................................................................................................................15717
13.2 Diesel engine............................................................................................................................................................................................................................................................................................................................................................................................................................................15717
13.3 Hybrid...................................................................................................................................................................................................................................................................................................................................................................................................................................................15718
14 Trailer weight - A8, type 4E...................................................................................................................................................................................................................................................................................................................................................................................................................................15719
14.1 Petrol engine............................................................................................................................................................................................................................................................................................................................................................................................................................................15719
14.2 Diesel engine............................................................................................................................................................................................................................................................................................................................................................................................................................................15720
15 Trailer weight - A8, type 4H...................................................................................................................................................................................................................................................................................................................................................................................................................................15722
15.1 Petrol engine............................................................................................................................................................................................................................................................................................................................................................................................................................................15722
15.2 Diesel engine............................................................................................................................................................................................................................................................................................................................................................................................................................................15722
15.3 Hybrid...................................................................................................................................................................................................................................................................................................................................................................................................................................................15723
16 Trailer weight - Q3, type 8U...................................................................................................................................................................................................................................................................................................................................................................................................................................15724
16.1 Petrol engine............................................................................................................................................................................................................................................................................................................................................................................................................................................15724
16.2 Diesel engine............................................................................................................................................................................................................................................................................................................................................................................................................................................15724
17 Trailer weight - Q5, type 8R...................................................................................................................................................................................................................................................................................................................................................................................................................................15725
17.1 Petrol engine............................................................................................................................................................................................................................................................................................................................................................................................................................................15725
17.2 Diesel engine............................................................................................................................................................................................................................................................................................................................................................................................................................................15725
17.3 Hybrid...................................................................................................................................................................................................................................................................................................................................................................................................................................................15726
18 Trailer weight - Q7, type 4L...................................................................................................................................................................................................................................................................................................................................................................................................................................15727
18.1 Petrol engine............................................................................................................................................................................................................................................................................................................................................................................................................................................15727
18.2 Diesel engine............................................................................................................................................................................................................................................................................................................................................................................................................................................15727
19 Trailer weight - Q7, type 4M...................................................................................................................................................................................................................................................................................................................................................................................................................................15729
19.1 Petrol engine............................................................................................................................................................................................................................................................................................................................................................................................................................................15729
19.1.1 Petrol engine - 3.0 ltr., 245 kW...................................................................................................................................................................................................................................................................................................................................................................................................................15729
19.2 Diesel engine............................................................................................................................................................................................................................................................................................................................................................................................................................................15729
19.2.1 Diesel engine - 3.0 ltr., 183 kW...................................................................................................................................................................................................................................................................................................................................................................................................................15729
19.2.2 Diesel engine - 3.0 ltr., 200 kW...................................................................................................................................................................................................................................................................................................................................................................................................................15730
Wheel_Tyre_Guide..........................................................................................................................................................................................................................................................................................................................................................................................................................................................15731
44 – Wheels, tyres, vehicle geometry..................................................................................................................................................................................................................................................................................................................................................................................................................................15735
1 Audi A5 Coupé, type 8T..........................................................................................................................................................................................................................................................................................................................................................................................................................................15735
1.1 Audi A5 Coupé, type 8T (model year 2008)..................................................................................................................................................................................................................................................................................................................................................................................................................15736
1.1.1 1.8 ltr. TFSI engine - 118 kW.......................................................................................................................................................................................................................................................................................................................................................................................................................15736
1.1.2 1.8 ltr. TFSI engine - 125 kW.......................................................................................................................................................................................................................................................................................................................................................................................................................15737
1.1.3 3.2 ltr. TFSI engine - 195 kW.......................................................................................................................................................................................................................................................................................................................................................................................................................15738
1.1.4 2.0 ltr. TDI engine - 120 kW........................................................................................................................................................................................................................................................................................................................................................................................................................15738
1.1.5 2.0 ltr. TDI engine - 125 kW........................................................................................................................................................................................................................................................................................................................................................................................................................15739
1.1.6 2.7 ltr. TDI engine - 120 kW........................................................................................................................................................................................................................................................................................................................................................................................................................15740
1.1.7 2.7 ltr. TDI engine - 140 kW........................................................................................................................................................................................................................................................................................................................................................................................................................15740
1.1.8 3.0 ltr. TDI engine - 155 kW........................................................................................................................................................................................................................................................................................................................................................................................................................15741
1.1.9 3.0 ltr. TDI engine - 176 kW........................................................................................................................................................................................................................................................................................................................................................................................................................15741
1.2 Audi A5 Coupé, type 8T (model year 2009)..................................................................................................................................................................................................................................................................................................................................................................................................................15743
1.2.1 1.8 ltr. TFSI engine - 118 kW.......................................................................................................................................................................................................................................................................................................................................................................................................................15743
1.2.2 1.8 ltr. TFSI engine - 125 kW.......................................................................................................................................................................................................................................................................................................................................................................................................................15744
1.2.3 2.0 ltr. TFSI engine - 132 kW.......................................................................................................................................................................................................................................................................................................................................................................................................................15744
1.2.4 2.0 ltr. TFSI engine - 155 kW.......................................................................................................................................................................................................................................................................................................................................................................................................................15745
1.2.5 3.2 ltr. TFSI engine - 195 kW.......................................................................................................................................................................................................................................................................................................................................................................................................................15746
1.2.6 2.0 ltr. TDI engine - 120 kW........................................................................................................................................................................................................................................................................................................................................................................................................................15746
1.2.7 2.0 ltr. TDI engine - 125 kW........................................................................................................................................................................................................................................................................................................................................................................................................................15747
1.2.8 2.7 ltr. TDI engine - 120 kW........................................................................................................................................................................................................................................................................................................................................................................................................................15747
1.2.9 2.7 ltr. TDI engine - 140 kW........................................................................................................................................................................................................................................................................................................................................................................................................................15748
1.2.10 3.0 ltr. TDI engine - 155 kW.......................................................................................................................................................................................................................................................................................................................................................................................................................15749
1.2.11 3.0 ltr. TDI engine - 176 kW.......................................................................................................................................................................................................................................................................................................................................................................................................................15749
1.3 Audi A5 Coupé, type 8T (model years 2010 to 2011).........................................................................................................................................................................................................................................................................................................................................................................................................15750
1.3.1 1.8 ltr. TFSI engine - 118 kW.......................................................................................................................................................................................................................................................................................................................................................................................................................15750
1.3.2 1.8 ltr. TFSI engine - 125 kW.......................................................................................................................................................................................................................................................................................................................................................................................................................15751
1.3.3 2.0 ltr. TFSI engine - 132 kW.......................................................................................................................................................................................................................................................................................................................................................................................................................15752
1.3.4 2.0 ltr. TFSI engine - 155 kW.......................................................................................................................................................................................................................................................................................................................................................................................................................15752
1.3.5 3.0 ltr. TFSI engine - 245 kW.......................................................................................................................................................................................................................................................................................................................................................................................................................15753
1.3.6 3.2 ltr. TFSI engine - 195 kW.......................................................................................................................................................................................................................................................................................................................................................................................................................15753
1.3.7 2.0 ltr. TDI engine - 100/105 kW....................................................................................................................................................................................................................................................................................................................................................................................................................15754
1.3.8 2.0 ltr. TDI engine - 120/125 kW....................................................................................................................................................................................................................................................................................................................................................................................................................15754
1.3.9 2.7 ltr. TDI engine - 120 kW........................................................................................................................................................................................................................................................................................................................................................................................................................15755
1.3.10 2.7 ltr. TDI engine - 140 kW.......................................................................................................................................................................................................................................................................................................................................................................................................................15756
1.3.11 3.0 ltr. TDI engine - 155 kW.......................................................................................................................................................................................................................................................................................................................................................................................................................15756
1.3.12 3.0 ltr. TDI engine - 176 kW.......................................................................................................................................................................................................................................................................................................................................................................................................................15757
1.4 Audi A5 Coupé, type 8T (model years 2012 to 2015).........................................................................................................................................................................................................................................................................................................................................................................................................15758
1.4.1 1.8 ltr. TFSI engine - 106 kW.......................................................................................................................................................................................................................................................................................................................................................................................................................15758
1.4.2 1.8 ltr. TFSI engine - 125 kW.......................................................................................................................................................................................................................................................................................................................................................................................................................15759
1.4.3 2.0 ltr. TFSI engine - 155 kW.......................................................................................................................................................................................................................................................................................................................................................................................................................15760
1.4.4 2.0 ltr. TFSI engine - 165 kW.......................................................................................................................................................................................................................................................................................................................................................................................................................15760
1.4.5 3.0 ltr. TFSI engine - 200 kW.......................................................................................................................................................................................................................................................................................................................................................................................................................15761
1.4.6 3.0 ltr. TFSI engine - 245 kW.......................................................................................................................................................................................................................................................................................................................................................................................................................15762
1.4.7 2.0 ltr. TDI engine - 100/105 kW....................................................................................................................................................................................................................................................................................................................................................................................................................15762
1.4.8 2.0 ltr. TDI engine - 110 kW........................................................................................................................................................................................................................................................................................................................................................................................................................15763
1.4.9 2.0 ltr. TDI engine - 120/125 kW....................................................................................................................................................................................................................................................................................................................................................................................................................15764
1.4.10 2.0 ltr. TDI engine - 130 kW.......................................................................................................................................................................................................................................................................................................................................................................................................................15764
1.4.11 3.0 ltr. TDI engine - 150 kW.......................................................................................................................................................................................................................................................................................................................................................................................................................15765
1.4.12 3.0 ltr. TDI engine - 160 kW.......................................................................................................................................................................................................................................................................................................................................................................................................................15766
1.4.13 3.0 ltr. TDI engine - 176 kW.......................................................................................................................................................................................................................................................................................................................................................................................................................15766
1.4.14 3.0 ltr. TDI engine - 180 kW (engine code CDUC / CKVB).............................................................................................................................................................................................................................................................................................................................................................................................15767
1.4.15 3.0 ltr. TDI engine - 180 kW (engine code CKVC only)...............................................................................................................................................................................................................................................................................................................................................................................................15768
1.5 General information - Audi A5 Coupé, type 8T..............................................................................................................................................................................................................................................................................................................................................................................................................15768
1.5.1 Changing to different wheel/tyre combinations to the tyre package...................................................................................................................................................................................................................................................................................................................................................................................15768
1.5.2 Definition of tyre package..........................................................................................................................................................................................................................................................................................................................................................................................................................15769
1.5.3 COC document (EC certificate of conformity).........................................................................................................................................................................................................................................................................................................................................................................................................15769
1.6 Audi A5 Coupé, type 8T (model years 2016 to 2017).........................................................................................................................................................................................................................................................................................................................................................................................................15770
1.6.1 1.8 ltr. TFSI engine - 106 kW.......................................................................................................................................................................................................................................................................................................................................................................................................................15771
1.6.2 1.8 ltr. TFSI engine - 125 kW.......................................................................................................................................................................................................................................................................................................................................................................................................................15772
1.6.3 1.8 ltr. TFSI engine - 130 kW.......................................................................................................................................................................................................................................................................................................................................................................................................................15773
1.6.4 2.0 ltr. TFSI engine - 165 kW.......................................................................................................................................................................................................................................................................................................................................................................................................................15773
1.6.5 2.0 ltr. TFSI engine - 169 kW.......................................................................................................................................................................................................................................................................................................................................................................................................................15774
1.6.6 3.0 ltr. TFSI engine - 200 kW.......................................................................................................................................................................................................................................................................................................................................................................................................................15775
1.6.7 3.0 ltr. TFSI engine - 245 kW.......................................................................................................................................................................................................................................................................................................................................................................................................................15775
1.6.8 2.0 ltr. TDI engine - 100 kW (vehicles with manual gearbox).........................................................................................................................................................................................................................................................................................................................................................................................15776
1.6.9 2.0 ltr. TDI engine - 100 kW (vehicles with automatic gearbox)......................................................................................................................................................................................................................................................................................................................................................................................15776
1.6.10 2.0 ltr. TDI engine - 120 kW.......................................................................................................................................................................................................................................................................................................................................................................................................................15777
1.6.11 2.0 ltr. TDI engine - 140 kW.......................................................................................................................................................................................................................................................................................................................................................................................................................15778
1.6.12 3.0 ltr. TDI engine - 160 kW.......................................................................................................................................................................................................................................................................................................................................................................................................................15778
1.6.13 3.0 ltr. TDI engine - 180 kW.......................................................................................................................................................................................................................................................................................................................................................................................................................15779
1.7 Temporary spare wheel - Coupé.............................................................................................................................................................................................................................................................................................................................................................................................................................15779
1.8 Audi S5 Coupé, type 8T (model year 2008)..................................................................................................................................................................................................................................................................................................................................................................................................................15780
1.8.1 4.2 ltr. engine - 260 kW............................................................................................................................................................................................................................................................................................................................................................................................................................15780
1.9 Audi S5 Coupé, type 8T (model years 2009 to 2011).........................................................................................................................................................................................................................................................................................................................................................................................................15781
1.9.1 3.0 ltr. TFSI engine - 245 kW.......................................................................................................................................................................................................................................................................................................................................................................................................................15781
1.9.2 4.2 ltr. TFSI engine - 260 kW.......................................................................................................................................................................................................................................................................................................................................................................................................................15781
1.10 Audi S5 Coupé, type 8T (model years 2012 to 2017)........................................................................................................................................................................................................................................................................................................................................................................................................15782
1.10.1 3.0 ltr. TFSI engine - 245 kW......................................................................................................................................................................................................................................................................................................................................................................................................................15782
1.10.2 4.2 ltr. TFSI engine - 260 kW......................................................................................................................................................................................................................................................................................................................................................................................................................15783
1.11 Audi RS 5 Coupé, type 8T (model years 2010 to 2017)......................................................................................................................................................................................................................................................................................................................................................................................................15783
1.11.1 4.2 ltr. engine - 331 kW...........................................................................................................................................................................................................................................................................................................................................................................................................................15783
2 Rims - Audi A5/S5 (Coupé, Sportback, Cabriolet).................................................................................................................................................................................................................................................................................................................................................................................................................15785
2.1 7.5 J x 16 rim............................................................................................................................................................................................................................................................................................................................................................................................................................................15785
2.2 7.5 J x 17 rim............................................................................................................................................................................................................................................................................................................................................................................................................................................15786
2.3 8 J x 17 rim..............................................................................................................................................................................................................................................................................................................................................................................................................................................15787
2.4 8 J x 18 rim..............................................................................................................................................................................................................................................................................................................................................................................................................................................15788
2.5 8.5 J x 18 rim............................................................................................................................................................................................................................................................................................................................................................................................................................................15788
2.6 8.5 J x 19 rim............................................................................................................................................................................................................................................................................................................................................................................................................................................15790
2.7 9 J x 19 rim..............................................................................................................................................................................................................................................................................................................................................................................................................................................15791
2.8 9 J x 20 rim..............................................................................................................................................................................................................................................................................................................................................................................................................................................15792
3 Rims - Audi RS 5 (Coupé, Sportback, Cabriolet)..................................................................................................................................................................................................................................................................................................................................................................................................................15794
3.1 8 J x 19 rim..............................................................................................................................................................................................................................................................................................................................................................................................................................................15794
3.2 9 J x 19 rim..............................................................................................................................................................................................................................................................................................................................................................................................................................................15794
3.3 9 J x 20 rim..............................................................................................................................................................................................................................................................................................................................................................................................................................................15795
4 Recommended tyres - Audi A5/S5, type 8T; Audi A5/S5 Cabriolet, type 8F..........................................................................................................................................................................................................................................................................................................................................................................................15798
4.1 Recommended summer tyres..................................................................................................................................................................................................................................................................................................................................................................................................................................15798
4.2 Recommended all-season tyres..............................................................................................................................................................................................................................................................................................................................................................................................................................15799
4.3 Recommended winter tyres..................................................................................................................................................................................................................................................................................................................................................................................................................................15799
5 Audi A5 Sportback...............................................................................................................................................................................................................................................................................................................................................................................................................................................15800
5.1 Audi A5 Sportback, type 8T (model years 2010 to 2011).....................................................................................................................................................................................................................................................................................................................................................................................................15801
5.1.1 1.8 ltr. TFSI engine - 118 kW.......................................................................................................................................................................................................................................................................................................................................................................................................................15801
5.1.2 1.8 ltr. TFSI engine - 125 kW.......................................................................................................................................................................................................................................................................................................................................................................................................................15802
5.1.3 2.0 ltr. TFSI engine - 132 kW.......................................................................................................................................................................................................................................................................................................................................................................................................................15803
5.1.4 2.0 ltr. TFSI engine - 155 kW.......................................................................................................................................................................................................................................................................................................................................................................................................................15803
5.1.5 2.0 ltr. TFSI engine - 162 kW.......................................................................................................................................................................................................................................................................................................................................................................................................................15804
5.1.6 3.2 ltr. TFSI engine - 195 kW.......................................................................................................................................................................................................................................................................................................................................................................................................................15804
5.1.7 2.0 ltr. TDI engine - 100 kW........................................................................................................................................................................................................................................................................................................................................................................................................................15805
5.1.8 2.0 ltr. TDI engine - 105 kW........................................................................................................................................................................................................................................................................................................................................................................................................................15805
5.1.9 2.0 ltr. TDI engine - 120 kW........................................................................................................................................................................................................................................................................................................................................................................................................................15806
5.1.10 2.0 ltr. TDI engine - 125 kW.......................................................................................................................................................................................................................................................................................................................................................................................................................15806
5.1.11 2.0 ltr. TDI engine - 130 kW.......................................................................................................................................................................................................................................................................................................................................................................................................................15807
5.1.12 2.7 ltr. TDI engine - 120 kW.......................................................................................................................................................................................................................................................................................................................................................................................................................15808
5.1.13 2.7 ltr. TDI engine - 140 kW.......................................................................................................................................................................................................................................................................................................................................................................................................................15808
5.1.14 3.0 ltr. TDI engine - 160 kW.......................................................................................................................................................................................................................................................................................................................................................................................................................15809
5.1.15 3.0 ltr. TDI engine - 176 kW.......................................................................................................................................................................................................................................................................................................................................................................................................................15809
5.2 Temporary spare wheel.....................................................................................................................................................................................................................................................................................................................................................................................................................................15810
5.3 General information - Audi A5 Sportback, type 8T..........................................................................................................................................................................................................................................................................................................................................................................................................15810
5.3.1 Changing to different wheel/tyre combinations to the tyre package...................................................................................................................................................................................................................................................................................................................................................................................15810
5.3.2 Definition of tyre package..........................................................................................................................................................................................................................................................................................................................................................................................................................15811
5.3.3 COC document (EC certificate of conformity).........................................................................................................................................................................................................................................................................................................................................................................................................15811
5.4 Audi A5 Sportback, type 8T (model years 2012 to 2015).....................................................................................................................................................................................................................................................................................................................................................................................................15812
5.4.1 1.8 ltr. TFSI engine - 106 kW.......................................................................................................................................................................................................................................................................................................................................................................................................................15813
5.4.2 1.8 ltr. TFSI engine - 118 kW.......................................................................................................................................................................................................................................................................................................................................................................................................................15814
5.4.3 1.8 ltr. TFSI engine - 125 kW.......................................................................................................................................................................................................................................................................................................................................................................................................................15815
5.4.4 1.8 ltr. TFSI engine - 130 kW.......................................................................................................................................................................................................................................................................................................................................................................................................................15816
5.4.5 2.0 ltr. TFSI engine - 132 kW.......................................................................................................................................................................................................................................................................................................................................................................................................................15816
5.4.6 2.0 ltr. TFSI engine - 155 kW.......................................................................................................................................................................................................................................................................................................................................................................................................................15817
5.4.7 2.0 ltr. TFSI engine - 162 kW.......................................................................................................................................................................................................................................................................................................................................................................................................................15818
5.4.8 2.0 ltr. TFSI engine - 165 kW.......................................................................................................................................................................................................................................................................................................................................................................................................................15819
5.4.9 3.0 ltr. TFSI engine - 200 kW.......................................................................................................................................................................................................................................................................................................................................................................................................................15819
5.4.10 3.0 ltr. TFSI engine - 245 kW......................................................................................................................................................................................................................................................................................................................................................................................................................15820
5.4.11 2.0 ltr. TDI engine - 100 kW.......................................................................................................................................................................................................................................................................................................................................................................................................................15821
5.4.12 2.0 ltr. TDI engine - 105 kW.......................................................................................................................................................................................................................................................................................................................................................................................................................15821
5.4.13 2.0 ltr. TDI engine - 110 kW.......................................................................................................................................................................................................................................................................................................................................................................................................................15822
5.4.14 2.0 ltr. TDI engine - 120 kW.......................................................................................................................................................................................................................................................................................................................................................................................................................15823
5.4.15 2.0 ltr. TDI engine - 130 kW.......................................................................................................................................................................................................................................................................................................................................................................................................................15824
5.4.16 2.0 ltr. TDI engine - 140 kW.......................................................................................................................................................................................................................................................................................................................................................................................................................15824
5.4.17 3.0 ltr. TDI engine - 150 kW.......................................................................................................................................................................................................................................................................................................................................................................................................................15825
5.4.18 3.0 ltr. TDI engine - 160 kW.......................................................................................................................................................................................................................................................................................................................................................................................................................15826
5.4.19 3.0 ltr. TDI engine - 180 kW (all engines except CKVC).............................................................................................................................................................................................................................................................................................................................................................................................15827
5.4.20 3.0 ltr. TDI engine - 180 kW (engine code CKVC)....................................................................................................................................................................................................................................................................................................................................................................................................15828
5.5 Temporary spare wheel - Sportback.........................................................................................................................................................................................................................................................................................................................................................................................................................15828
5.6 Audi A5 Sportback, type 8T (model years 2016 to 2017).....................................................................................................................................................................................................................................................................................................................................................................................................15828
5.6.1 1.8 ltr. TFSI engine - 106 kW.......................................................................................................................................................................................................................................................................................................................................................................................................................15829
5.6.2 1.8 ltr. TFSI engine - 125 kW.......................................................................................................................................................................................................................................................................................................................................................................................................................15830
5.6.3 1.8 ltr. TFSI engine - 130 kW.......................................................................................................................................................................................................................................................................................................................................................................................................................15831
5.6.4 2.0 ltr. TFSI engine - 165 kW.......................................................................................................................................................................................................................................................................................................................................................................................................................15831
5.6.5 2.0 ltr. TFSI engine - 169 kW.......................................................................................................................................................................................................................................................................................................................................................................................................................15832
5.6.6 3.0 ltr. TFSI engine - 200 kW.......................................................................................................................................................................................................................................................................................................................................................................................................................15833
5.6.7 3.0 ltr. TFSI engine - 245 kW.......................................................................................................................................................................................................................................................................................................................................................................................................................15833
5.6.8 2.0 ltr. TDI engine - 100 kW (vehicles with manual gearbox).........................................................................................................................................................................................................................................................................................................................................................................................15834
5.6.9 2.0 ltr. TDI engine - 100 kW (vehicles with automatic gearbox)......................................................................................................................................................................................................................................................................................................................................................................................15834
5.6.10 2.0 ltr. TDI engine - 110 kW.......................................................................................................................................................................................................................................................................................................................................................................................................................15835
5.6.11 2.0 ltr. TDI engine - 120 kW.......................................................................................................................................................................................................................................................................................................................................................................................................................15836
5.6.12 2.0 ltr. TDI engine - 140 kW.......................................................................................................................................................................................................................................................................................................................................................................................................................15836
5.6.13 3.0 ltr. TDI engine - 160 kW.......................................................................................................................................................................................................................................................................................................................................................................................................................15837
5.6.14 3.0 ltr. TDI engine - 180 kW.......................................................................................................................................................................................................................................................................................................................................................................................................................15838
5.7 Audi S5 Sportback, type 8T (model year 2010)..............................................................................................................................................................................................................................................................................................................................................................................................................15838
5.7.1 3.0 ltr. TFSI engine - 245 kW.......................................................................................................................................................................................................................................................................................................................................................................................................................15838
5.8 Audi S5 Sportback, type 8T (model years 2011 to 2017).....................................................................................................................................................................................................................................................................................................................................................................................................15839
5.8.1 3.0 ltr. TFSI engine - 245 kW.......................................................................................................................................................................................................................................................................................................................................................................................................................15839
5.8.2 4.2 ltr. TFSI engine - 260 kW.......................................................................................................................................................................................................................................................................................................................................................................................................................15840
5.9 Audi RS 5 Sportback, type 8T (model years 2010 to 2017)...................................................................................................................................................................................................................................................................................................................................................................................................15840
5.9.1 4.2 ltr. engine - 331 kW............................................................................................................................................................................................................................................................................................................................................................................................................................15840
6 Recommended tyres - Audi A5 Sportback, type 8T .................................................................................................................................................................................................................................................................................................................................................................................................................15842
6.1 Recommended summer tyres..................................................................................................................................................................................................................................................................................................................................................................................................................................15842
6.2 Recommended all-season tyres..............................................................................................................................................................................................................................................................................................................................................................................................................................15843
6.3 Recommended winter tyres..................................................................................................................................................................................................................................................................................................................................................................................................................................15843
7 Audi A5 Cabriolet, type 8F......................................................................................................................................................................................................................................................................................................................................................................................................................................15844
7.1 Audi A5 Cabriolet, type 8F (model years 2010 to 2011).....................................................................................................................................................................................................................................................................................................................................................................................................15845
7.1.1 1.8 ltr. TFSI engine - 118 kW.......................................................................................................................................................................................................................................................................................................................................................................................................................15845
7.1.2 2.0 ltr. TFSI engine - 132 kW.......................................................................................................................................................................................................................................................................................................................................................................................................................15846
7.1.3 2.0 ltr. TFSI engine - 155 kW.......................................................................................................................................................................................................................................................................................................................................................................................................................15847
7.1.4 3.2 ltr. TFSI engine - 195 kW.......................................................................................................................................................................................................................................................................................................................................................................................................................15847
7.1.5 2.0 ltr. TDI engine - 120 kW........................................................................................................................................................................................................................................................................................................................................................................................................................15848
7.1.6 2.0 ltr. TDI engine - 125 kW........................................................................................................................................................................................................................................................................................................................................................................................................................15848
7.1.7 2.7 ltr. TDI engine - 120 kW........................................................................................................................................................................................................................................................................................................................................................................................................................15849
7.1.8 2.7 ltr. TDI engine - 140 kW........................................................................................................................................................................................................................................................................................................................................................................................................................15850
7.1.9 3.0 ltr. TDI engine - 176 kW........................................................................................................................................................................................................................................................................................................................................................................................................................15850
7.1.10 3.0 ltr. TDI engine - 180 kW (engine code CKVC)....................................................................................................................................................................................................................................................................................................................................................................................................15851
7.1.11 3.0 ltr. TDI engine - 180 kW (all engines except CKVC).............................................................................................................................................................................................................................................................................................................................................................................................15851
7.2 Temporary spare wheel.....................................................................................................................................................................................................................................................................................................................................................................................................................................15852
7.3 General information - Audi A5 Cabriolet, type 8F..........................................................................................................................................................................................................................................................................................................................................................................................................15852
7.3.1 Changing to different wheel/tyre combinations to the tyre package...................................................................................................................................................................................................................................................................................................................................................................................15852
7.3.2 Definition of tyre package..........................................................................................................................................................................................................................................................................................................................................................................................................................15853
7.3.3 COC document (EC certificate of conformity).........................................................................................................................................................................................................................................................................................................................................................................................................15853
7.4 Audi A5 Cabriolet, type 8F (model years 2012 to 2015).....................................................................................................................................................................................................................................................................................................................................................................................................15854
7.4.1 1.8 ltr. TFSI engine - 106 kW.......................................................................................................................................................................................................................................................................................................................................................................................................................15855
7.4.2 1.8 ltr. TFSI engine - 118 kW.......................................................................................................................................................................................................................................................................................................................................................................................................................15856
7.4.3 1.8 ltr. TFSI engine - 125 kW.......................................................................................................................................................................................................................................................................................................................................................................................................................15857
7.4.4 1.8 ltr. TFSI engine - 130 kW.......................................................................................................................................................................................................................................................................................................................................................................................................................15858
7.4.5 2.0 ltr. TFSI engine - 132 kW.......................................................................................................................................................................................................................................................................................................................................................................................................................15858
7.4.6 2.0 ltr. TFSI engine - 155 kW.......................................................................................................................................................................................................................................................................................................................................................................................................................15859
7.4.7 2.0 ltr. TFSI engine - 162 kW.......................................................................................................................................................................................................................................................................................................................................................................................................................15860
7.4.8 2.0 ltr. TFSI engine - 165 kW.......................................................................................................................................................................................................................................................................................................................................................................................................................15861
7.4.9 3.0 ltr. TFSI engine - 200 kW.......................................................................................................................................................................................................................................................................................................................................................................................................................15861
7.4.10 3.0 ltr. TFSI engine - 245 kW......................................................................................................................................................................................................................................................................................................................................................................................................................15862
7.4.11 2.0 ltr. TDI engine - 100 kW.......................................................................................................................................................................................................................................................................................................................................................................................................................15863
7.4.12 2.0 ltr. TDI engine - 105 kW.......................................................................................................................................................................................................................................................................................................................................................................................................................15863
7.4.13 2.0 ltr. TDI engine - 110 kW.......................................................................................................................................................................................................................................................................................................................................................................................................................15864
7.4.14 2.0 ltr. TDI engine - 120 kW.......................................................................................................................................................................................................................................................................................................................................................................................................................15865
7.4.15 2.0 ltr. TDI engine - 130 kW.......................................................................................................................................................................................................................................................................................................................................................................................................................15866
7.4.16 2.0 ltr. TDI engine - 140 kW.......................................................................................................................................................................................................................................................................................................................................................................................................................15866
7.4.17 3.0 ltr. TDI engine - 150 kW.......................................................................................................................................................................................................................................................................................................................................................................................................................15867
7.4.18 3.0 ltr. TDI engine - 160 kW.......................................................................................................................................................................................................................................................................................................................................................................................................................15868
7.4.19 3.0 ltr. TDI engine - 180 kW (all engines except CKVC).............................................................................................................................................................................................................................................................................................................................................................................................15869
7.4.20 3.0 ltr. TDI engine - 180 kW (engine code CKVC)....................................................................................................................................................................................................................................................................................................................................................................................................15870
7.5 Audi A5 Cabriolet, type 8F (model years 2016 to 2017).....................................................................................................................................................................................................................................................................................................................................................................................................15870
7.5.1 1.8 ltr. TFSI engine - 106 kW.......................................................................................................................................................................................................................................................................................................................................................................................................................15871
7.5.2 1.8 ltr. TFSI engine - 125 kW.......................................................................................................................................................................................................................................................................................................................................................................................................................15872
7.5.3 1.8 ltr. TFSI engine - 130 kW.......................................................................................................................................................................................................................................................................................................................................................................................................................15872
7.5.4 2.0 ltr. TFSI engine - 165 kW.......................................................................................................................................................................................................................................................................................................................................................................................................................15873
7.5.5 2.0 ltr. TFSI engine - 169 kW.......................................................................................................................................................................................................................................................................................................................................................................................................................15874
7.5.6 3.0 ltr. TFSI engine - 200 kW.......................................................................................................................................................................................................................................................................................................................................................................................................................15874
7.5.7 3.0 ltr. TFSI engine - 245 kW.......................................................................................................................................................................................................................................................................................................................................................................................................................15875
7.5.8 2.0 ltr. TDI engine - 110 kW........................................................................................................................................................................................................................................................................................................................................................................................................................15876
7.5.9 2.0 ltr. TDI engine - 140 kW........................................................................................................................................................................................................................................................................................................................................................................................................................15876
7.5.10 3.0 ltr. TDI engine - 160 kW.......................................................................................................................................................................................................................................................................................................................................................................................................................15877
7.5.11 3.0 ltr. TDI engine - 180 kW.......................................................................................................................................................................................................................................................................................................................................................................................................................15878
7.6 Temporary spare wheel, Cabriolet..........................................................................................................................................................................................................................................................................................................................................................................................................................15878
8 Audi S5 Cabriolet, type 8F......................................................................................................................................................................................................................................................................................................................................................................................................................................15879
8.1 Audi S5 Cabriolet, type 8F (model years 2010 to 2011).....................................................................................................................................................................................................................................................................................................................................................................................................15879
8.1.1 3.0 ltr. TFSI engine - 245 kW.......................................................................................................................................................................................................................................................................................................................................................................................................................15879
8.1.2 4.2 ltr. TFSI engine - 260 kW.......................................................................................................................................................................................................................................................................................................................................................................................................................15880
8.2 Audi S5 Cabriolet, type 8F (model years 2012 to 2017).....................................................................................................................................................................................................................................................................................................................................................................................................15880
8.2.1 3.0 ltr. TFSI engine - 245 kW.......................................................................................................................................................................................................................................................................................................................................................................................................................15880
8.2.2 4.2 ltr. TFSI engine - 260 kW.......................................................................................................................................................................................................................................................................................................................................................................................................................15881
9 Audi RS 5 Cabriolet, type 8F....................................................................................................................................................................................................................................................................................................................................................................................................................................15882
9.1 4.2 ltr. TFSI engine - 331 kW.............................................................................................................................................................................................................................................................................................................................................................................................................................15882
10 Tyre pressures.................................................................................................................................................................................................................................................................................................................................................................................................................................................15883
10.1 Tyre pressures - Audi A5 Coupé, type 8T..................................................................................................................................................................................................................................................................................................................................................................................................................15883
10.1.1 1.8 ltr. TFSI engine - 125 kW......................................................................................................................................................................................................................................................................................................................................................................................................................15883
10.1.2 2.0 ltr. TFSI engine - 132 kW......................................................................................................................................................................................................................................................................................................................................................................................................................15884
10.1.3 2.0 ltr. TFSI engine - 155 kW......................................................................................................................................................................................................................................................................................................................................................................................................................15885
10.1.4 2.0 ltr. TFSI engine - 162 kW......................................................................................................................................................................................................................................................................................................................................................................................................................15885
10.1.5 2.0 ltr. TFSI engine - 165 kW......................................................................................................................................................................................................................................................................................................................................................................................................................15886
10.1.6 3.2 ltr. FSI engine - 195 kW.......................................................................................................................................................................................................................................................................................................................................................................................................................15887
10.1.7 3.0 ltr. TFSI engine - 200 kW......................................................................................................................................................................................................................................................................................................................................................................................................................15887
10.1.8 3.0 ltr. TFSI engine - 245 kW (S5).................................................................................................................................................................................................................................................................................................................................................................................................................15888
10.1.9 4.2 ltr. FSI engine - 260 kW (S5)..................................................................................................................................................................................................................................................................................................................................................................................................................15888
10.1.10 2.0 ltr. TDI engine - 100 kW......................................................................................................................................................................................................................................................................................................................................................................................................................15889
10.1.11 2.0 ltr. TDI engine - 105 kW......................................................................................................................................................................................................................................................................................................................................................................................................................15889
10.1.12 2.0 ltr. TDI engine - 110 kW......................................................................................................................................................................................................................................................................................................................................................................................................................15890
10.1.13 2.0 ltr. TDI engine - 120 kW......................................................................................................................................................................................................................................................................................................................................................................................................................15890
10.1.14 2.0 ltr. TDI engine - 130 kW......................................................................................................................................................................................................................................................................................................................................................................................................................15891
10.1.15 2.7 ltr. TDI engine - 120 kW......................................................................................................................................................................................................................................................................................................................................................................................................................15892
10.1.16 2.7 ltr. TDI engine - 140 kW......................................................................................................................................................................................................................................................................................................................................................................................................................15892
10.1.17 3.0 ltr. TDI engine - 150 kW......................................................................................................................................................................................................................................................................................................................................................................................................................15893
10.1.18 3.0 ltr. TDI engine - 155 kW......................................................................................................................................................................................................................................................................................................................................................................................................................15893
10.1.19 3.0 ltr. TDI engine - 176 kW......................................................................................................................................................................................................................................................................................................................................................................................................................15894
10.1.20 3.0 ltr. TDI engine - 180 kW......................................................................................................................................................................................................................................................................................................................................................................................................................15895
10.1.21 2.0 ltr. TDI engine - 120 kW (e model)............................................................................................................................................................................................................................................................................................................................................................................................................15895
10.1.22 S5 Coupé..........................................................................................................................................................................................................................................................................................................................................................................................................................................15896
10.2 Tyre pressures - Audi A5 Sportback, type 8T..............................................................................................................................................................................................................................................................................................................................................................................................................15897
10.2.1 1.8 ltr. TFSI engine - 125 kW......................................................................................................................................................................................................................................................................................................................................................................................................................15897
10.2.2 2.0 ltr. TFSI engine - 132 kW......................................................................................................................................................................................................................................................................................................................................................................................................................15898
10.2.3 2.0 ltr. TFSI engine - 155 kW......................................................................................................................................................................................................................................................................................................................................................................................................................15898
10.2.4 2.0 ltr. TFSI engine - 162 kW......................................................................................................................................................................................................................................................................................................................................................................................................................15899
10.2.5 2.0 ltr. TFSI engine - 165 kW......................................................................................................................................................................................................................................................................................................................................................................................................................15900
10.2.6 3.0 ltr. TFSI engine - 200 kW......................................................................................................................................................................................................................................................................................................................................................................................................................15900
10.2.7 3.0 ltr. TFSI engine - 245 kW......................................................................................................................................................................................................................................................................................................................................................................................................................15901
10.2.8 3.2 ltr. FSI engine - 195 kW.......................................................................................................................................................................................................................................................................................................................................................................................................................15901
10.2.9 4.2 ltr. FSI engine - 260 kW.......................................................................................................................................................................................................................................................................................................................................................................................................................15902
10.2.10 3.0 ltr. TFSI engine - 245 kW.....................................................................................................................................................................................................................................................................................................................................................................................................................15902
10.2.11 2.0 ltr. TDI engine - all power ratings...........................................................................................................................................................................................................................................................................................................................................................................................................15903
10.2.12 2.7 ltr. TDI engine - 120 kW......................................................................................................................................................................................................................................................................................................................................................................................................................15903
10.2.13 2.7 ltr. TDI engine - 140 kW......................................................................................................................................................................................................................................................................................................................................................................................................................15904
10.2.14 3.0 ltr. TDI engine - 150 kW......................................................................................................................................................................................................................................................................................................................................................................................................................15905
10.2.15 3.0 ltr. TDI engine - 155 kW......................................................................................................................................................................................................................................................................................................................................................................................................................15905
10.2.16 3.0 ltr. TDI engine - 175 kW......................................................................................................................................................................................................................................................................................................................................................................................................................15906
10.2.17 3.0 ltr. TDI engine - 180 kW......................................................................................................................................................................................................................................................................................................................................................................................................................15906
10.2.18 2.0 ltr. TDI engine - 100 kW (e model)............................................................................................................................................................................................................................................................................................................................................................................................................15907
10.2.19 2.0 ltr. TDI engine - 120 kW (e model)............................................................................................................................................................................................................................................................................................................................................................................................................15907
10.2.20 S5 Sportback......................................................................................................................................................................................................................................................................................................................................................................................................................................15908
10.3 Tyre pressures - Audi A5 Cabriolet, type 8F..............................................................................................................................................................................................................................................................................................................................................................................................................15909
10.3.1 1.8 ltr. TFSI engine - 118 kW......................................................................................................................................................................................................................................................................................................................................................................................................................15909
10.3.2 1.8 ltr. TFSI engine - 125 kW......................................................................................................................................................................................................................................................................................................................................................................................................................15910
10.3.3 2.0 ltr. TFSI engine - 132 kW......................................................................................................................................................................................................................................................................................................................................................................................................................15911
10.3.4 2.0 ltr. TFSI engine - 155 kW......................................................................................................................................................................................................................................................................................................................................................................................................................15911
10.3.5 3.2 ltr. FSI engine - 195 kW.......................................................................................................................................................................................................................................................................................................................................................................................................................15912
10.3.6 3.0 ltr. TFSI engine - 200 kW......................................................................................................................................................................................................................................................................................................................................................................................................................15913
10.3.7 3.0 ltr. TFSI engine - 245 kW (S5).................................................................................................................................................................................................................................................................................................................................................................................................................15913
10.3.8 2.0 ltr. TDI engine - 100 kW.......................................................................................................................................................................................................................................................................................................................................................................................................................15914
10.3.9 2.0 ltr. TDI engine - 105 kW.......................................................................................................................................................................................................................................................................................................................................................................................................................15915
10.3.10 2.0 ltr. TDI engine - 110 kW......................................................................................................................................................................................................................................................................................................................................................................................................................15915
10.3.11 2.0 ltr. TDI engine - 120 kW......................................................................................................................................................................................................................................................................................................................................................................................................................15916
10.3.12 2.0 ltr. TDI engine - 130 kW......................................................................................................................................................................................................................................................................................................................................................................................................................15917
10.3.13 2.7 ltr. TDI engine - 120 kW......................................................................................................................................................................................................................................................................................................................................................................................................................15917
10.3.14 2.7 ltr. TDI engine - 140 kW......................................................................................................................................................................................................................................................................................................................................................................................................................15918
10.3.15 3.0 ltr. TDI engine - 150 kW......................................................................................................................................................................................................................................................................................................................................................................................................................15919
10.3.16 3.0 ltr. TDI engine - 165 kW......................................................................................................................................................................................................................................................................................................................................................................................................................15919
10.3.17 3.0 ltr. TDI engine - 176 kW......................................................................................................................................................................................................................................................................................................................................................................................................................15920
10.3.18 3.0 ltr. TDI engine - 180 kW......................................................................................................................................................................................................................................................................................................................................................................................................................15921
10.3.19 S5 Cabriolet......................................................................................................................................................................................................................................................................................................................................................................................................................................15921
Wheels_and_tyres..........................................................................................................................................................................................................................................................................................................................................................................................................................................................15923
44 – Wheels, tyres, vehicle geometry..................................................................................................................................................................................................................................................................................................................................................................................................................................15929
1 Requirements for retrofitting different wheel/tyre combinations (documents).....................................................................................................................................................................................................................................................................................................................................................................................15929
1.1 Legal requirements........................................................................................................................................................................................................................................................................................................................................................................................................................................15929
1.2 Technical requirements....................................................................................................................................................................................................................................................................................................................................................................................................................................15930
1.3 Registration documents since 1 October 2005...............................................................................................................................................................................................................................................................................................................................................................................................................15930
1.4 COC document (EC certificate of conformity)...............................................................................................................................................................................................................................................................................................................................................................................................................15931
2 General information.............................................................................................................................................................................................................................................................................................................................................................................................................................................15933
3 Tightening torques for wheel bolts..............................................................................................................................................................................................................................................................................................................................................................................................................................15934
3.1 Tightening torques for wheel bolts - current models.......................................................................................................................................................................................................................................................................................................................................................................................................15934
3.2 Tightening torques for wheel bolts - other models.........................................................................................................................................................................................................................................................................................................................................................................................................15935
4 Re-tightening wheel bolts.......................................................................................................................................................................................................................................................................................................................................................................................................................................15936
5 Permissible differences in tread depth..........................................................................................................................................................................................................................................................................................................................................................................................................................15937
5.1 Models with longitudinally installed engine...............................................................................................................................................................................................................................................................................................................................................................................................................15937
5.2 Models with transversely installed engine.................................................................................................................................................................................................................................................................................................................................................................................................................15938
6 Recommended snow chains.........................................................................................................................................................................................................................................................................................................................................................................................................................................15939
6.1 Recommended snow chains - RUD.............................................................................................................................................................................................................................................................................................................................................................................................................................15939
6.1.1 Recommended snow chains - RUD (14 inch).............................................................................................................................................................................................................................................................................................................................................................................................................15939
6.1.2 Recommended snow chains - RUD (15 inch).............................................................................................................................................................................................................................................................................................................................................................................................................15939
6.1.3 Recommended snow chains - RUD (16 inch).............................................................................................................................................................................................................................................................................................................................................................................................................15939
6.1.4 Recommended snow chains - RUD (17 inch).............................................................................................................................................................................................................................................................................................................................................................................................................15940
6.1.5 Recommended snow chains - RUD (18 inch).............................................................................................................................................................................................................................................................................................................................................................................................................15940
6.1.6 Recommended snow chains - RUD (19 inch).............................................................................................................................................................................................................................................................................................................................................................................................................15940
6.1.7 Recommended snow chains - RUD (20 inch).............................................................................................................................................................................................................................................................................................................................................................................................................15940
6.2 Recommended snow chains - König...........................................................................................................................................................................................................................................................................................................................................................................................................................15941
6.2.1 Recommended snow chains - König (14 inch)...........................................................................................................................................................................................................................................................................................................................................................................................................15941
6.2.2 Recommended snow chains - König (15 inch)...........................................................................................................................................................................................................................................................................................................................................................................................................15941
6.2.3 Recommended snow chains - König (16 inch)...........................................................................................................................................................................................................................................................................................................................................................................................................15941
6.2.4 Recommended snow chains - König (17 inch)...........................................................................................................................................................................................................................................................................................................................................................................................................15941
6.2.5 Recommended snow chains - König (18 inch)...........................................................................................................................................................................................................................................................................................................................................................................................................15942
6.2.6 Recommended snow chains - König (19 inch)...........................................................................................................................................................................................................................................................................................................................................................................................................15942
7 Additional wheel housing extensions (flaps).....................................................................................................................................................................................................................................................................................................................................................................................................................15943
8 Rims with bonded wheel trim.....................................................................................................................................................................................................................................................................................................................................................................................................................................15944
9 Rims with exchangeable trim elements (bonded)...................................................................................................................................................................................................................................................................................................................................................................................................................15945
9.1 Removing trim element.....................................................................................................................................................................................................................................................................................................................................................................................................................................15945
9.2 Installing trim element...................................................................................................................................................................................................................................................................................................................................................................................................................................15947
10 Rims with exchangeable trim elements (bolted)..................................................................................................................................................................................................................................................................................................................................................................................................................15950
11 Split-rim composite wheels.....................................................................................................................................................................................................................................................................................................................................................................................................................................15951
12 Wheel bolts....................................................................................................................................................................................................................................................................................................................................................................................................................................................15952
12.1 Anti-theft wheel bolts...................................................................................................................................................................................................................................................................................................................................................................................................................................15953
12.2 Adapter sets for anti-theft wheel bolts..................................................................................................................................................................................................................................................................................................................................................................................................................15953
13 Fitting wheels / tyres / Tyre Pressure Monitoring System / Tyre Pressure Loss Indicator........................................................................................................................................................................................................................................................................................................................................................................15955
13.1 General information on wheels and tyres..................................................................................................................................................................................................................................................................................................................................................................................................................15955
13.2 Exploded view of components for light alloy wheels.......................................................................................................................................................................................................................................................................................................................................................................................................15955
13.3 Exploded view of components for PAX run-flat tyres.......................................................................................................................................................................................................................................................................................................................................................................................................15956
13.4 Instructions for changing/fitting wheels.................................................................................................................................................................................................................................................................................................................................................................................................................15958
13.5 Removing and fitting run-flat tyres......................................................................................................................................................................................................................................................................................................................................................................................................................15963
13.6 Safety notes for run-flat tyres..........................................................................................................................................................................................................................................................................................................................................................................................................................15964
13.7 Conditions for fitting run-flat tyres....................................................................................................................................................................................................................................................................................................................................................................................................................15965
13.8 Unseating run-flat tyres.................................................................................................................................................................................................................................................................................................................................................................................................................................15966
13.9 Removing run-flat tyres..................................................................................................................................................................................................................................................................................................................................................................................................................................15967
13.10 Fitting run-flat tyres..................................................................................................................................................................................................................................................................................................................................................................................................................................15968
13.11 Exploded view of Tyre Pressure Monitoring System........................................................................................................................................................................................................................................................................................................................................................................................................15971
13.12 Changing a tyre.........................................................................................................................................................................................................................................................................................................................................................................................................................................15973
13.13 Removing and installing metal valve body................................................................................................................................................................................................................................................................................................................................................................................................................15974
13.14 Wheel electronics (TPMS) - Beru system..................................................................................................................................................................................................................................................................................................................................................................................................................15979
13.15 Wheel electronics (TPMS) - Siemens system...............................................................................................................................................................................................................................................................................................................................................................................................................15980
14 Wheel electronics - new design.................................................................................................................................................................................................................................................................................................................................................................................................................................15981
15 Repairing slight damage on rims................................................................................................................................................................................................................................................................................................................................................................................................................................15982
16 Identification markings on the tyre sidewall...................................................................................................................................................................................................................................................................................................................................................................................................................15983
16.1 Designations on sidewall of tyres with run-flat system (PAX).............................................................................................................................................................................................................................................................................................................................................................................................15985
16.2 EU tyre label............................................................................................................................................................................................................................................................................................................................................................................................................................................15986
16.2.1 EU tyre label - overview...........................................................................................................................................................................................................................................................................................................................................................................................................................15986
16.2.2 EU tyre label - objectives.........................................................................................................................................................................................................................................................................................................................................................................................................................15987
16.2.3 EU tyre label - categories.........................................................................................................................................................................................................................................................................................................................................................................................................................15988
17 Tyre requirements and tyre maintenance.........................................................................................................................................................................................................................................................................................................................................................................................................................15991
17.1 Introduction.............................................................................................................................................................................................................................................................................................................................................................................................................................................15991
17.2 Requirements to be met by tyres..........................................................................................................................................................................................................................................................................................................................................................................................................................15992
17.3 Factors influencing the service life of a tyre...........................................................................................................................................................................................................................................................................................................................................................................................................15992
17.4 Tyre pressure (maintenance)..............................................................................................................................................................................................................................................................................................................................................................................................................................15993
17.5 Driving style............................................................................................................................................................................................................................................................................................................................................................................................................................................15994
17.6 Measuring tread depth....................................................................................................................................................................................................................................................................................................................................................................................................................................15995
17.7 Speed rating / maximum speed.............................................................................................................................................................................................................................................................................................................................................................................................................................15996
17.8 Speed symbols for tyres..................................................................................................................................................................................................................................................................................................................................................................................................................................15996
17.9 Winter tyres with speed symbol “V”.......................................................................................................................................................................................................................................................................................................................................................................................................................15997
17.10 Load rating code/load index (LI)........................................................................................................................................................................................................................................................................................................................................................................................................................15998
17.11 Reinforced/Extra Load (XL) tyres........................................................................................................................................................................................................................................................................................................................................................................................................................15999
17.12 Extra Load (XL) V winter tyres..........................................................................................................................................................................................................................................................................................................................................................................................................................15999
17.13 Snow chains.............................................................................................................................................................................................................................................................................................................................................................................................................................................15999
17.14 The valve...............................................................................................................................................................................................................................................................................................................................................................................................................................................16000
17.15 Tyre storage............................................................................................................................................................................................................................................................................................................................................................................................................................................16000
17.16 Storing the tyres.......................................................................................................................................................................................................................................................................................................................................................................................................................................16001
17.17 Tyre ageing.............................................................................................................................................................................................................................................................................................................................................................................................................................................16001
17.18 Renewing tyres..........................................................................................................................................................................................................................................................................................................................................................................................................................................16002
17.19 Care and maintenance of alloy wheel rims................................................................................................................................................................................................................................................................................................................................................................................................................16002
17.20 Tyres with rim protectors...............................................................................................................................................................................................................................................................................................................................................................................................................................16003
18 Tyre wear / mileage............................................................................................................................................................................................................................................................................................................................................................................................................................................16004
18.1 General notes............................................................................................................................................................................................................................................................................................................................................................................................................................................16004
18.2 Wear of high-speed tyres.................................................................................................................................................................................................................................................................................................................................................................................................................................16004
18.3 Evenly worn tyres........................................................................................................................................................................................................................................................................................................................................................................................................................................16004
18.4 One-sided wear...........................................................................................................................................................................................................................................................................................................................................................................................................................................16004
18.5 Permissible differences in tread depth...................................................................................................................................................................................................................................................................................................................................................................................................................16005
18.6 One-sided wear - adjustment error........................................................................................................................................................................................................................................................................................................................................................................................................................16005
18.7 Wear in middle of tyre...................................................................................................................................................................................................................................................................................................................................................................................................................................16006
18.8 Diagonal erosion.........................................................................................................................................................................................................................................................................................................................................................................................................................................16006
18.9 Wear - adjustment error..................................................................................................................................................................................................................................................................................................................................................................................................................................16007
19 Permissible differences in tread depth.........................................................................................................................................................................................................................................................................................................................................................................................................................16008
19.1 Models with longitudinally installed engine..............................................................................................................................................................................................................................................................................................................................................................................................................16008
19.2 Models with transversely installed engine................................................................................................................................................................................................................................................................................................................................................................................................................16009
20 Tyre noise.....................................................................................................................................................................................................................................................................................................................................................................................................................................................16010
20.1 General notes on tyre noise..............................................................................................................................................................................................................................................................................................................................................................................................................................16010
20.2 Saw-tooth wear...........................................................................................................................................................................................................................................................................................................................................................................................................................................16010
20.3 Flat spots (brake-flatting)..............................................................................................................................................................................................................................................................................................................................................................................................................................16011
21 Rough running caused by wheels/tyres...........................................................................................................................................................................................................................................................................................................................................................................................................................16013
21.1 Causes of rough running..................................................................................................................................................................................................................................................................................................................................................................................................................................16013
21.2 Flat spots caused by storage or handling.................................................................................................................................................................................................................................................................................................................................................................................................................16013
22 Wheel balancing................................................................................................................................................................................................................................................................................................................................................................................................................................................16015
22.1 General notes............................................................................................................................................................................................................................................................................................................................................................................................................................................16015
22.2 Conducting a road test before balancing wheels...........................................................................................................................................................................................................................................................................................................................................................................................................16015
22.3 Balancing wheels on stationary wheel balancer............................................................................................................................................................................................................................................................................................................................................................................................................16016
22.4 Wheels with sensitive surfaces and bonded wheel trims....................................................................................................................................................................................................................................................................................................................................................................................................16017
22.5 Work sequence when balancing wheels and tyres............................................................................................................................................................................................................................................................................................................................................................................................................16017
22.6 Finish balancer..........................................................................................................................................................................................................................................................................................................................................................................................................................................16019
22.7 Vibration control system -VAS 6230 A-....................................................................................................................................................................................................................................................................................................................................................................................................................16021
22.8 Radial and lateral run-out on wheel/tyre.................................................................................................................................................................................................................................................................................................................................................................................................................16021
22.9 Checking radial and lateral run-out of wheels and tyres on V.A.G 1435....................................................................................................................................................................................................................................................................................................................................................................................16021
22.10 Checking radial and lateral run-out of wheels and tyres with wheel balancing machine centring system -VAS 5271-.........................................................................................................................................................................................................................................................................................................................................16022
22.11 Checking radial and lateral run-out on rim..............................................................................................................................................................................................................................................................................................................................................................................................................16023
22.12 Match mounting..........................................................................................................................................................................................................................................................................................................................................................................................................................................16024
23 Vehicle pulls to one side......................................................................................................................................................................................................................................................................................................................................................................................................................................16026
23.1 General notes............................................................................................................................................................................................................................................................................................................................................................................................................................................16026
23.2 Remedies when vehicle pulls to one side..................................................................................................................................................................................................................................................................................................................................................................................................................16027
23.3 Strategic rotation of wheels for non-directional tyres...................................................................................................................................................................................................................................................................................................................................................................................................16028
23.4 Strategic rotation of wheels for unidirectional tyres....................................................................................................................................................................................................................................................................................................................................................................................................16029
24 Tyre damage....................................................................................................................................................................................................................................................................................................................................................................................................................................................16031
24.1 General notes............................................................................................................................................................................................................................................................................................................................................................................................................................................16031
24.2 Checking tyres...........................................................................................................................................................................................................................................................................................................................................................................................................................................16031
24.3 Construction of belted radial tyres......................................................................................................................................................................................................................................................................................................................................................................................................................16032
24.4 Torn tread...............................................................................................................................................................................................................................................................................................................................................................................................................................................16033
24.5 Undulations..............................................................................................................................................................................................................................................................................................................................................................................................................................................16033
24.6 Impact damage............................................................................................................................................................................................................................................................................................................................................................................................................................................16033
24.7 Cuts.....................................................................................................................................................................................................................................................................................................................................................................................................................................................16034
24.8 Damage caused by foreign bodies..........................................................................................................................................................................................................................................................................................................................................................................................................................16034
24.9 Loss of air from tyre....................................................................................................................................................................................................................................................................................................................................................................................................................................16035
24.10 Damage occurring when fitting tyres.....................................................................................................................................................................................................................................................................................................................................................................................................................16035
24.11 Bead damage caused by fitting machine...................................................................................................................................................................................................................................................................................................................................................................................................................16036
24.12 Tyre pressure...........................................................................................................................................................................................................................................................................................................................................................................................................................................16037
24.13 Tyre damage due to insufficient inflation pressure......................................................................................................................................................................................................................................................................................................................................................................................................16037
24.14 Slow loss of tyre pressure..............................................................................................................................................................................................................................................................................................................................................................................................................................16037
24.15 Temperature increase caused by insufficient inflation pressure..........................................................................................................................................................................................................................................................................................................................................................................................16038
24.16 Tears in tyre...........................................................................................................................................................................................................................................................................................................................................................................................................................................16038
25 Vehicles with breakdown set....................................................................................................................................................................................................................................................................................................................................................................................................................................16039
25.1 Tyre sealant.............................................................................................................................................................................................................................................................................................................................................................................................................................................16039
25.2 Removing a tyre from the rim.............................................................................................................................................................................................................................................................................................................................................................................................................................16039
25.3 Disposal of sealant......................................................................................................................................................................................................................................................................................................................................................................................................................................16040
25.4 Fitting a new tyre.......................................................................................................................................................................................................................................................................................................................................................................................................................................16040
26 Tyre Pressure Monitoring Systems/Tyre Pressure Loss Indicator..................................................................................................................................................................................................................................................................................................................................................................................................16041
26.1 Tyre Pressure Monitoring System with pressure sensor.....................................................................................................................................................................................................................................................................................................................................................................................................16041
26.2 Tyre Pressure Loss Indicator with wheel speed sensor.....................................................................................................................................................................................................................................................................................................................................................................................................16042
27 Temporary spare wheels.........................................................................................................................................................................................................................................................................................................................................................................................................................................16043
27.1 Notes on the use of temporary spare wheels...............................................................................................................................................................................................................................................................................................................................................................................................................16043
28 Run-flat tyres.................................................................................................................................................................................................................................................................................................................................................................................................................................................16044
28.1 Renewing tyres/conditions for use of run-flat tyres......................................................................................................................................................................................................................................................................................................................................................................................................16044
28.2 Tyres with run-flat capability (PAX).....................................................................................................................................................................................................................................................................................................................................................................................................................16044
28.2.1 Construction of tyres with run-flat capability (PAX)...............................................................................................................................................................................................................................................................................................................................................................................................16045
28.2.2 Codes and designations on tyres with run-flat capability (PAX).....................................................................................................................................................................................................................................................................................................................................................................................16047
28.2.3 Support ring on PAX wheels.........................................................................................................................................................................................................................................................................................................................................................................................................................16047
28.2.5 Inflating tyres on PAX wheels......................................................................................................................................................................................................................................................................................................................................................................................................................16048
28.2.6 Wheel alignment....................................................................................................................................................................................................................................................................................................................................................................................................................................16049
28.2.7 Repairing tyres with run-flat capability (PAX).....................................................................................................................................................................................................................................................................................................................................................................................................16049
28.2.8 PAX tyres - assessing condition....................................................................................................................................................................................................................................................................................................................................................................................................................16050
28.2.9 Checking support ring..............................................................................................................................................................................................................................................................................................................................................................................................................................16050
28.3 Self supporting tyres (SST) with run-flat capability.....................................................................................................................................................................................................................................................................................................................................................................................................16051
28.3.1 Design of an SST tyre..............................................................................................................................................................................................................................................................................................................................................................................................................................16052
28.4 Tyres with run-flat capability (Seal Inside technology)..................................................................................................................................................................................................................................................................................................................................................................................................16054
28.4.1 Design of a Seal Inside tyre.......................................................................................................................................................................................................................................................................................................................................................................................................................16055
28.4.2 Function of a Seal Inside tyre.....................................................................................................................................................................................................................................................................................................................................................................................................................16055
28.5 Servicing tyres with run-flat capability.................................................................................................................................................................................................................................................................................................................................................................................................................16056
PLEASE NOTE:
This is the SAME exact manual used by your dealers to fix your vehicle.
The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
Any queries / doubts regarding your purchase, please feel free to contact [email protected]
SK
✹
What Our Customers Say
★★★★★Live reviews from customers
Loading customer reviews...
🌟 Related Products
Discover more professional manuals for your equipment
