002 Maintenance

2005 Audi A4 Quattro
Maintenance Maintenance Procedures - Cabriolet
Maintenance
Maintenance Procedures - Cabriolet
01 - MAINTENANCE
ENGINE OVERVIEW
NOTE:  Some engines listed below are for European models.
Gasoline engines
1*) 91 RON standard unleaded gasoline is permissible, however with decreased power output.
2*) 95 RON Super unleaded gasoline is permissible, however with decreased power output.
cardiagn.com
Diesel engines
1*) Engine code AVF 3.0 Nm
DELIVERY INSPECTION
Delivery inspection
For information regarding Inspection Service refer to ServiceNet; Delivery Satisfaction; Perfect Delivery
Inspection (PDI) forms for appropriate model and year.
OIL CHANGE SERVICE
Oil change service
For engine oil specifications and capacities please refer to ServiceNet; Additional Information; Fluid Capacity
Chart for appropriate model and year
Also, for appropriate service intervals refer to ServiceNet; Maintenance Schedule for appropriate model year
INSPECTION SERVICE
Inspection Service
12:53:55 AM
12:54:06 Page 1
For appropriate service intervals refer to ServiceNet; Maintenance Schedule for appropriate model year
DESCRIPTION OF WORK
All switches, all electrical components, all displays and other operating elements: Checking function
 Check following:
 Lighting, headlamps, fog lights, turn signals, hazard warning flashers, taillights, rear fog lights, backup
lights, brake lights, parking lights
 Interior and reading lights (automatic shutoff on interior lights), illuminated storage compartment,
illuminated ashtray, luggage compartment lighting, illuminated ignition
 Warning buzzer for lights and/or radio left on
 All switches in console
cardiagn.com
 Driver Information System (DIS)
 Instrument unit with all displays, meters and lights
 Two-tone horn
 Windshield/headlamp wipers, headlamp cleaning system
 Cigarette lighter
 Electric exterior mirrors (heated, adjustable)
 Electric windows
 Electric tilt/slide sunroof
 Central locking, remote control operation, comfort closing

 Electric seat
 Heated seat
 Radio
Final drive (automatic transmission): Check oil level, add oil if necessary
Automatic transmission
--> -
 39 - FINAL DRIVE, DIFFERENTIAL for 5 SPD. AUTOMATIC TRANSMISSION 01V

 39 FINAL DRIVE - FRONT DIFFERENTIAL for 6 SPD. AUTOMATIC TRANSMISSION 09L ALL
WHEEL DRIVE
Continuously Variable Transmission (CVT)
--> - 39 - FINAL DRIVE, DIFFERENTIAL
12:53:55 AM Page 2
Battery: Check
Battery with "magic eye"
Battery is located in plenum chamber between engine compartment and windshield or in spare wheel well on
RS4.
cardiagn.com
Fig. 1: Pushing Cover Over Battery Toward Right And Removing It Upward
Courtesy of VOLKSWAGEN UNITED STATES, INC.
 Slide cover over battery to right - arrow 1 - and remove upward - arrow 2 -.
Fig. 2: Identifying The Visual Indicator

 The visual indicator - arrow - gives information about electrolyte level and battery charge.
 Switch ignition off.
12:53:56 AM Page 3

 Check electrolyte level at visual indicator - arrow -.
cardiagn.com
 Tap lightly on battery housing with a blunt object, air bubbles under the visual indicator can cause a false
reading.
 Green battery charge is OK.
 Black no charge or charge too low
 No color or yellow critical electrolyte level has been reached, battery must be replaced --> - 27
BATTERY, STARTER, GENERATOR, CRUISE CONTROL
NOTE:  Observe before disconnecting battery --> Note before disconnecting

battery.
Battery sealing plugs
 On batteries with visible min and max markings, electrolyte level only needs to be checked visually.
 Electrolyte level must be between min. and max. markings.
 On batteries where the outer min. and max. markings are difficult to see or the visibility of the electrolyte
level cannot be guaranteed due to the opaque battery housing, the sealing plugs must be removed. Then it
is possible to check electrolyte level by a visual inspection of the battery interior.
 The electrolyte level must meet the inner electrolyte level marking (plastic bar). This corresponds to the
outer max. mark.
NOTE:  If electrolyte level is too low, battery loses capacity (loses performance)
because the cell plates dry out. If the cell plates are not covered by
electrolyte, the plates and plate bridges start to corrode causing the
function of the battery to diminish. After a while the battery does no longer
function. The battery becomes useless.
WARNING: If the electrolyte level is below them in. marking, the battery must be
12:53:56 AM Page 4
replaced! --> - 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL
Valve-regulated lead acid battery or absorbed glass mat (AGM) battery
NOTE:  Valve-regulated lead acid or AGM batteries are sealed, they cannot and
must not be opened. --> - 27 BATTERY, STARTER, GENERATOR, CRUISE
CONTROL
Battery: No load voltage, checking before starting engine for the first time
Necessary test equipment
 Digital multimeter V.A.G 17.5
or
cardiagn.com
 Portable multimeter V.A.G 1526 B
Fig. 4: Special Tool - Multimeter V.A.G 1526 A

Portable multimeter
NOTE:  Battery must not be loaded by connected components for at least 12 hours
before testing.
 Battery must not be charged for at least 12 hours before testing.
 Measure voltage between terminals with engine switched off.
WARNING: Always follow procedure exactly, otherwise measured values could be

incorrect.
Battery: Ensure battery cable fits securely
12:53:56 AM Page 5
Fig. 5: Locating Battery Terminals On Battery

 Check battery terminals on vehicle battery for secure fit, tighten nuts on -terminal -1- and + terminal - 2 -
if necessary.
cardiagn.com
WARNING: If the battery clamp is not seated securely on the positive terminal,
disconnect battery Ground (GND) strap on battery negative terminal first,
to prevent possible accidents.

battery.

 Check battery for secure fit, tighten screws - 4 - on securing bracket - 3 - if necessary.
Battery: Perform battery load test
Battery load test indicates battery condition.
Special tools, testers, and measuring equipment
12:53:56 AM Page 6
Fig. 7: Battery VAS Tester

 Battery tester VAS 5097 A
cardiagn.com
NOTE:  If battery tester VAS 5097A is used, it is not necessary to remove battery.
The battery does not need to be disconnected either.
Perform battery load test

 Read battery tester operating instructions.
 Connect test lead clamps to battery terminals as shown in battery tester operating instructions.
The clamps must make good contact with battery poles.
 Load current depends on battery capacity and must be adjusted on the tester battery tester operating
instructions.
 Perform battery load test according to operating instructions.
Tester display during battery load test
Note following tester evaluations:
Table:
 Replace battery. --> - 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL
Regarding battery load test:
Because of the high load on the battery during this test (a high current flows) the battery voltage lowers.
If the battery is OK, the voltage only goes down to the minimum voltage specification.
12:53:56 AM Page 7
If the battery is malfunctioning or only faintly charged, the battery voltage will drop rapidly to below the
displayed minimum voltage.
After the test, this low voltage remains steady over a longer time before the voltage slowly increases.
Brake fluid level, dependent on lining wear: Check
NOTE:  Use only new Original VW / Audi brake fluid, see ETKA
WARNING:  Brake fluid is poisonous. Due to its caustic nature, it must also
never be brought into contact with paint.
 Brake fluid is hygroscopic, meaning that it absorbs moisture from
the surrounding air, and must therefore always be stored in air-tight
containers.
cardiagn.com
 Please observe the following:
Delivery inspection
Fig. 8: Identifying Fluid Level

 Fluid level must be at MAX mark
NOTE:  To prevent the brake fluid from overflowing from the reservoir, the level
must not be over the MAX mark.
Inspection service
When driving, fluid level drops slightly from use and automatic brake pad adjustment.
 Always check fluid level in conjunction with brake pad wear:
12:53:56 AM Page 8

 When brake pads are new or if there is still enough brake lining left, the brake fluid level must be
between MIN and MAX marks.
cardiagn.com
 With brake fluid at MIN mark or slightly above, topping off brake fluid is not necessary when wear limit
of brake pads has been almost reached.
WARNING: If brake fluid level is below MIN mark, check brake system (repair
procedure), before adding brake fluid.
Brake fluid: Changing
Fig. 10: Identifying Brake Filler And Bleeder Unit VAS 5234
 VAS 52.4 Brake filling and bleeding tool
12:53:56 AM Page 9
Fig. 11: Identifying Brake Filler And Bleeder Unit V.A.G 1869
 V.A.G 1869 Brake filling and bleeding tool with Adapter set V.A.G 1869/4
cardiagn.com
WARNING:  Brake fluid must never come into contact with fluids containing
mineral oils (oil, gas, cleaning solutions). Oils containing minerals
damage seals and sleeves on brake systems.
 Brake fluid is poisonous. Due to its caustic nature, it must also
 Brake fluid is hygroscopic, which means that it absorbs moisture
from the air. Always store brake fluid in air-tight containers.
 Wash off brake fluid spillage using plenty of water.
 Observe waste disposal regulations!
Observe operating instructions for VAS 52.4 or for V.A.G 1869 !
Fig. 12: Identifying Brake Fluid Reservoir Cap

12:53:56 AM Page 10
 Remove brake fluid reservoir cap - 1 -.
WARNING:  The strainer in the brake fluid reservoir must not be removed.
 Remove brake fluid reservoir plug - arrow -.
cardiagn.com
Fig. 13: Connecting Suction Hose From VAS 52.4 Or V.A.G 1869 To Tube Of Brake Fluid Reservoir
 Connect suction hose from VAS 52.4 or V.A.G 1869 to tube - 1 - of brake fluid reservoir.
 Extract as much brake fluid as possible using suction hose from VAS 52.4 or from V.A.G 1869 or with
extractor bottle.
 Disconnect suction hose.
12:53:56 AM Page 11
 Connect suction hose from VAS 52.4 or V.A.G 1869 to tube - 2 - of brake fluid reservoir.
 Extract as much brake fluid as possible using suction hose from VAS 52.4 or from V.A.G 1869 or with
extractor bottle.
 Install brake fluid reservoir plug.
WARNING: Do not reuse, (used) extracted brake fluid.
cardiagn.com
Fig. 15: Connecting Filler Hose From VAS 52.4 Or V.A.G 1869 To Adapter
 Install adapter - 1 - to brake fluid reservoir.

 Connect filler hose - 2 - from VAS 52.4 or V.A.G 1869 to adapter.
Vehicles with manual transmission:
 Pull cover cap off clutch slave cylinder bleed screw.
12:53:56 AM Page 12
cardiagn.com
 Place extractor bleeder hose - 1 - on clutch slave cylinder bleeder screw, open bleeder screw, and let
about 100 ml drain out. Close bleeder screw and install cover cap.
 Operate clutch pedal several times.
Continued for all vehicles:
 Remove caps from the bleeder screws.

 Connect extractor bleeder hose - 1 - to front left bleeder screw, open bleeder screw and allow about 2.0
ml to flow out. Close bleeder screw.
Repeat work sequence on other side of vehicle at front.

12:53:56 AM Page 13
 Connect extractor bleeder hose - 1 - to rear left bleeder screw, open bleeder screw and allow about 2.0 ml
to flow out. Close bleeder screw.
Repeat work sequence on other side of vehicle at rear.
Table - Sequence / quantity of brake fluid
* Including brake fluid extracted from brake fluid reservoir and quantity from clutch slave cylinder.
 Fit cover caps to brake caliper bleed screws.

 Move filler lever on VAS 52.4 or V.A.G 1869 to position - B - (see operating instructions).
 Take filler hose off adapter.
 Unscrew adapter from brake fluid reservoir.
cardiagn.com
 Check brake fluid level and correct if necessary.

 Install cap to brake fluid reservoir.
 Check pedal pressure and brake pedal free play. Free play: Max. 1 / 3 of pedal travel
Brake system: Visual inspection for leaks and damage
 Check the following components for leaks and damage:
 Brake master cylinder

 Brake booster
 ABS Hydraulic unit
 Brake calipers
 Check that brake hoses are not twisted.

 Ensure brake hoses do not come in contact with any vehicle components when steering is at full lock.
12:53:56 AM Page 14
 Check brake hoses for porosity, bubbles and cracks.

 Check brake hoses and pipes for chafing.
 Check all brake line connections for secure mounting, leaks, or corrosion.
WARNING: Malfunctions found must be rectified (repair measure).
Brake pads: Thickness, checking
WARNING: At a pad thickness of 7 mm (including backing plate) the brake pads have
reached their wear limit and must be replaced (repair measure). Inform the
customer.
Front disc brake pads:
cardiagn.com
 Determine thickness of outer pads by checking visually (using a flashlight through a hole in wheel).
Fig. 19: Identifying Thickness Of The Inner Pad

 Determine thickness of the inner pad by visual check (using a flashlight through a hole in the wheel).
Rear disc brake pads:
12:53:56 AM Page 15

cardiagn.com
Tires: Checking condition, wear pattern and tread depth and adjusting tire pressure.
Tires, checking
NOTE:  For reasons of safety only tires of same type and tread pattern should be
fitted on a vehicle!
 On All Wheel Drive vehicle tires of the same type and tread pattern must
be used. Otherwise the center differential may be damaged.
Delivery inspection
 Check running surfaces and side walls for damage, remove foreign bodies, if necessary.
Inspection service
 Check tires for scuffing, one sided wear, porous side walls, cuts and fractures.
WARNING: Report any damage to customer and mark repair order accordingly.
Checking tire wear pattern
 The wear pattern of the front wheels can be used to assess whether a check of the track and camber is
necessary:
 Feathered edges of the treads may indicate faulty toe adjustment.

 One-sided tread wear is mainly attributed to incorrect camber.
12:53:56 AM Page 16
NOTE:  When wear of this nature is noticed determine cause by performing

alignment checks (repair measure).
Check tread depth.
 Minimum depth: 1.6 mm
NOTE:  This value may vary for individual countries due to different legislative
regulations.
cardiagn.com
Fig. 21: Checking Tire Tread Depth
 The minimum tread depth is reached when the tires have worn down level
with the 1.6 mm high tread wear indicators - arrows - positioned at
intervals around the tire.
 If the tread depth is approaching the legal minimum permissible depth, the
customer must be informed.
Tire pressure, adjusting
Fig. 22: Identifying Tire Pressure Values For Summer Tires On Sticker
12:53:56 AM Page 17
Tire pressure values for summer tires are on the sticker on the inside of the fuel tank flap.
NOTE:  Observe that the inflation pressure specifications on the sticker refer to
the air pressure of cold tires. Do not reduce increased pressures on warm
tires.
 When using winter tires, the tire pressure must be increased about 0.2 bar.
Spare wheel
 Spare wheel with standard tire
Keep the highest pressure intended for the vehicle
 Mini spare tire
cardiagn.com
Pressure is on side of tire
 Tire repair kit
Check --> Tire repair kit: Checking
NOTE:  Tire valves must be sealed with valve caps. Otherwise, dirt can enter valve
needle which becomes jammed and can no seal shut.
Set digital clock
Vehicle is equipped with a radio or quartz clock.
Radio clock
If an acceptable radio clock signal is received, clock automatically switches to "radio-controlled quartz clock"
operating mode. The radio clock reception symbol (radio tower radiating waves) appears in display. If the clock
does not receive a valid signal, it automatically switches to "quartz clock" mode after 3 days and radio clock
reception symbol goes out.
Quartz clock
Set hour
 Press "MODE" button; hour display blinks.

 Press "+" button to advance hour display.
 Press "-" button to reverse hour display.
Set minute
12:53:56 AM Page 18
 Press "MODE" button until minute display blinks.

 Press "+" button to advance minute display.
 Press "-" button to reverse minute display.
Set date
 Press "MODE" button until date display blinks.

 Press "+" or "-" button to set day.
 Press "MODE" button again, month display blinks.
 Press "+" or "-" button to set month.
 Press "MODE" button again, year display blinks.

 Press "+" or "-" button to set year.
cardiagn.com
DTC memory: Retrieving with VAS 5051/ 5052
 Follow these steps in sequential order.
Fig. 23: Connecting Diagnostic Lead Connector VAS 5051/1 Or VAS 5051/3 At Data Link Connector
(DLC)
 Connect VAS 5051/5052

 Use auxiliary K-lead adapter VAS 6017B
 Vehicle - Self-diagnosis
 Gateway - Installation list
12:53:56 AM Page 19
 Read control module with stored DTC memory.

 Correct relevant malfunctions with customers approval.
Electric windows: Check positioning
Electric windows forget current position and automatic lowering and raising function when battery is
disconnected.
Activate automatic lowering/raising function as follows:
 Switch ignition on.

 Raise windows with electric window regulators up to stop.
 Then operate all window switches again for at least 1 second in "close" position to activate automatic
lowering/raising.
 Press switch down. Window must lower to stop by itself.
cardiagn.com
Check vehicle key function
 Separate keys so that each can be checked individually for function.

 Mechanically lock and unlock drivers door with each key.
 Insert each key in ignition and switch ignition on. Immobilizer key symbol in instrument cluster must go
out after two seconds. If key symbol blinks, key is not programmed to immobilizer. Guided Fault
Finding; Program vehicle key
NOTE:  Enter number of keys checked and delivered to customer in delivery

protocol.
Noise insulation: Removing
Vehicles with auxiliary heater:
Fig. 24: Identifying Exhaust Pipe Fasteners

12:53:56 AM Page 20
 Remove parking/auxiliary heater exhaust pipe screws - arrows - on noise insulation.
All:
cardiagn.com
Fig. 25: Removing Sound Insulation
 Remove quick-release screws - arrows -.
Rear lid hinges: Lubricate
 Open rear lid

 Remove left/right lid hinge cover if present.
Fig. 26: Lubricating Hinge Joints

 Lubricate the four hinge joints on both rear lid hinges at the left and right of the hinge guides - arrows -.
 Lubricant: "G 000 115 A2"
NOTE:  Included spray tube must be inserted in sprayer head to aim spray.
12:53:56 AM Page 21
 Shake spray can about five times.

 Spray must not be shaken too long or hard because otherwise spray oil
will foam up and its lubricating ability is reduced.
 Clean excess oil from body and joints.
Power steering fluid: Check for leaks and fluid level, top off fluid, if necessary
 With engine not running, move front wheels in straight-ahead position.
Cold fluid (exterior temperature approx +20 C)
 Remove cover.
 Clean dipstick with clean cloth.
 Screw cap on hand-tight and remove again.
cardiagn.com
Screw cap fully in to get an accurate fluid level reading.
Fig. 27: Checking Fluid Level

 Check fluid level: Fluid level must be in area of "MAX" marking.
Warm fluid (engine oil temperature +80 C)
 Check fluid level: Fluid level must be 10 mm above "MAX" marking.
NOTE:  If fluid level is above specified range, fluid must be extracted off.
 If the fluid level is below the specified level, check the power steering
system for leaks. It is not enough to simply top off with fluid.
 Do not use power steering fluid that has drained out.
Calibrate rearview mirror with compass
12:53:56 AM Page 22
--> - 68 - INTERIOR EQUIPMENT
A/C system: Check function, set temperature to 72 F (22 C)
 Check all climate control functions: Owners manual
cardiagn.com
Fig. 28: Checking Whether 72F (22C ) Is Set In Both Display Fields
 Check whether 72F (22C ) is set in both display fields.

 Set temperature as follows, if necessary:
 Press the "AUTO" button.
 Set temperature on drivers and passengers side to 72F (22C) with "+" and "-" buttons.
Instrument cluster: Adapt language version
12:53:56 AM Page 23
cardiagn.com
(DLC)

 Guided Fault Finding or Guided Functions
 Go to - function/component selection
 Service work
 Language adaptation
 Now follow guided program
NOTE:  Please follow guided program function description

 K-lead adapter VAS 6017B must be used.
Cooling system: Check freeze protection, add coolant, if necessary
NOTE:  All new engines are filled with coolant additive G 12 Plus according to TL
VW 774 F (purple color). G 12 Plus can be mixed with the previous coolant
additives G 11 and G 12 (red). Ensure that the system is replenished only
with G12 Plus (due to its positive properties).
 G 12 Plus is suitable as a filled-for-life filling for cast iron and all-aluminum
engines and gives optimum protection against freezing, corrosion
damage, scaling and over-heating.
 G 12 Plus increases the boiling point to 2.5F (135C) and ensures for a
12:53:56 AM Page 24
better heat dissipation.

 The coolant portion of the mixture must amount to at least 40% (freeze
protection to -13F [-25C]) and should not exceed 60% (freeze protection to
-40F [-40C]). Otherwise the freeze protection will be reduced and the
cooling efficiency will be worsened.
 The freeze protection must be ensured to approximately -13F (-25 C).
Checking freeze protection and adding coolant additive if necessary
Special tools, testers and auxiliary items required
cardiagn.com
Fig. 30: Identifying Refractometer T10007
 Refractometer T10007
NOTE:  Read the bright/dark boundary to obtain an accurate reading for the
following tests. Place a drop of water on the glass to improve the
readability of the bright/dark boundary. The bright/dark boundary can be
clearly recognized on the "WATERLINE".
 Check the concentration of the coolant additive using refractometer
T10007 (operating instructions).
12:53:56 AM Page 25
Fig. 31: Identifying Refractometer Scales

The scale - 1 - of the refractometer is designed for coolant additives G 12; G12 Plus and G11.
cardiagn.com
Scale - 2 - refers only to coolant additive G 13. (previously L80)
NOTE:  The freeze protection must be ensured to approximately -13F [-25C].

 If for climatic reasons greater freeze protection is required, the amount of
G 12 Plus can be increased, but only up to 60% (freeze protection to about
-40F [-40C]), otherwise freeze protection and cooling effectiveness will be
reduced.
 If freeze protection is insufficient, drain off required quantity shown in
freeze protection table and add coolant additive G 12 Plus.
NOTE:  Observe waste disposal regulations!

 Check coolant additive concentration after test drive again.
Checking coolant level and adding coolant if necessary
 Check coolant level in expansion tank with engine cold.
12:53:56 AM Page 26
Fig. 32: Checking Coolant Level

 Delivery inspection: Coolant level above the "MIN marking" - arrow -.

 Inspection service: Coolant level above the "MIN marking" - arrow -.
 If coolant is too low, add required amount according to mixture ratio.
NOTE:  Determine cause of fluid loss which cannot be attributed to normal use
and rectify (repair measure).
Mixture ratio:
NOTE:  Coolant additive G 12 Plus conforming to TL VW 774 F prevents freeze and

corrosion damage, scaling, and raises the boiling point. For these
cardiagn.com
reasons, the cooling system must be filled with radiator freeze and
corrosion protection fluid all year round.
 Especially in countries with tropical climates or when vehicle is driven
under heavy load, the coolant improves the engine reliability by its
increased boiling point.
 The coolant concentration must not be reduced by adding water, even
during the warmer season. The coolant additive ratio must be at least 40%.
Ribbed belt: Replacing
8-cyl. 5V engines 4.2L
 Ribbed belt, removing and installing: --> -

 13 - ENGINE - CRANKSHAFT, CYLINDER BLOCK for 4.2 LITER V8 5V ENGINE
MECHANICAL, ENGINE CODE(S): BHF
Air cleaner: Clean air filter housing and replace filter
All:
12:53:56 AM Page 27
Fig. 33: Identifying Cover

 If present, remove cover - 1 - upward.
cardiagn.com
All:
Fig. 34: Identifying Intake Hose And EVAP Valve Retainer

 Remove intake hose - A - upward, pull tab - 1 - (if present) out of EVAP valve retainer.
 Remove both screws - 2 - and remove air intake hose - B -.
NOTE:  In various engine versions, a snow screen is located in intake hose - A -.

Screen must be removed and cleaned.
4-cyl. 2.0L FSI engines --> 4-cyl. 2.0L FSI engines
4-cyl. 1.8L Turbo engines --> 4-cyl. 1.8L Turbo engines
6-cyl. 3.0L MPI engines --> 6-cyl. 3.0L MPI engines
6-cyl. 3.2L FSI engines --> 6-cyl. 3.2L FSI engines
12:53:56 AM Page 28
8-cyl. 4.2L FSI engines (RS4) --> 8-cyl. 4.2L engines (RS4)
4-cyl. 2.0L FSI engines
cardiagn.com
Fig. 35: Evaporative Emission Canister Purge Regulator Valve N80 And Air Duct
 Remove bolts - arrows -.

 Remove air duct - 2 -.
Fig. 36: Identifying Air Intake Hose, Electrical Connector, And Mass Air Flow (MAF) Sensor G70
 Remove air intake hose - 4 - and disconnect electrical connector - 3 - from Mass Air Flow (MAF) Sensor
G70.
 Remove both screws - 2 - at upper part of air filter and remove upward.
 Remove old air filter element.
 Clean filter housing and install new air filter element.
 Further assembly occurs in reverse order.
12:53:56 AM Page 29
 Follow notes * See footnote
4-cyl. 1.8L Turbo engines
cardiagn.com

Fig. 38: Identifying Hose Clamp And Evaporative Emission (EVAP) Canister Valve
 Open hose clamp - 1 - and remove line from Evaporative Emission (EVAP) canister valve.
 Remove line - 3 - and remove both screws - 2 -.
 Remove upper part of air filter from bracket and pivot toward engine side.

12:53:56 AM Page 30
6-cyl. 3.0L MPI engines
cardiagn.com
 Disengage Evaporative Emission (EVAP) Canister Purge Regulator Valve N80 - 1 - at air duct.
Fig. 40: Identifying Air Duct, Air Intake Hose, Electrical Connector And Mass Air Flow (MAF) Sensor
G70

G70.
 Remove both fuel lines from bracket on upper part of air filter housing.
 Disconnect pipe connection - 1 -.
12:53:56 AM Page 31
6-cyl. 3.2L FSI engines
cardiagn.com
Fig. 42: Identifying Air Duct, Clean Air Tube Clamp, Fuel Line, And Pipe Connection

 Open clean air tube clamp - 4 - and remove from air filter housing.
 Unclip fuel line - 3 -.
12:53:57 AM Page 32
cardiagn.com
G70.
 Remove line -1- and remove both screws - 2 -.
 Remove both fuel lines from bracket on upper part of air filter and remove this upward.

12:53:57 AM Page 33
8-cyl. 4.2L engines (RS4)
cardiagn.com
 Disengage fuel line - 1 - at upper part of air filter housing.

Fig. 46: Identifying Air Duct And Mass Air Flow Sensor G70 Electrical Connector

 Loosen hose clamp - 2 - and remove air intake hose from upper part of air filter.
 Disconnect electrical connector - 1 - from Mass Air Flow Sensor G70.
 Remove hoses - 6 - , - 4 - and - 3 - from bracket.
 Now remove screws - 5 - and remove upper part of air filter housing upward.
12:53:57 AM Page 34
*- Note
NOTE:  If the air filter insert is heavily soiled or soaked, dirt particles or moisture
can reach the Mass Air Flow Sensor G70 and cause an incorrect air flow
reading. This causes lack of performance because a lower injection
amount is calculated.
 Always use an original air filter insert.
 Hose supports and charge air system hoses must be free of oil and grease
before installation. Do not use any lubricant containing silicone when
installing.
cardiagn.com
 Air filter housing must be clean.
 Secure all hose connections with hose clamps that match current
standard production.
 When cleaning air filter housing with compressed air, observe the
following: To avoid malfunctions, cover critical air carrying engine
components such as Mass Air Flow (MAF) sensor, air inlet tube, etc. with a
clean cloth.
 Check drain hose in bottom side of air filter or dirt and adhesion (clean, if
necessary).
 Check mass air flow sensor and air guide hose (clean air side) for salt
residue, dirt and leaves.
 Check air duct from lock carrier to air filter housing for dirt and leaves.
 When installing air filter insert, ensure it is centered in mount on bottom of
air filter.
 Carefully and gently place upper part of air filter on lower part. Ensure
upper part of air filter is not sitting crooked on air filter insert (note air filter
insert sealing lip).
 Ensure secure fit from air guide hose to Mass Air Flow (MAF) Sensor G70.
Engine oil: Fill
NOTE:  Please follow specified engine oil capacity and oil standards in the ELSA
maintenance table.
 Engine oil conforming to standard VW 507 00 must be used in vehicles
equipped with diesel particle filter.
Engines with turbocharger:
12:53:57 AM Page 35
 After the engine oil and oil filter have been replaced, observe the following when first starting the engine:
 As long as the oil pressure warning light in the instrument panel insert flashes, the engine is only to run at
idle. Do not touch the accelerator pedal! Bumping the accelerator pedal can damage the turbocharger or
destroy it completely
 The full oil pressure achieved and the engine can be accelerated only when the warning light extinguishes
All:
 Check engine oil level --> Engine: Oil level, checking
Engine: Oil level, checking
NOTE:  Oil temperature at least 140F (60C).

 Vehicle must be in level position.
cardiagn.com
 After stopping engine, wait a few minutes to allow oil to flow back into oil
pan.
 Pull out oil dipstick and wipe with clean rag. Replace dipstick and push
down to stop.
 Pull out dipstick again and read oil level.
Fig. 47: Identifying Markings On Dipstick

Markings on dipstick:
NOTE:  Oil level must not exceed - a - mark on dipstick.
Engine cover: Removing
12:53:57 AM Page 36
Fig. 48: Removing Engine Cover

4-cyl. gasoline engines
cardiagn.com
 Remove bolts or nuts - arrows - and remove engine cover(s).
Fig. 49: Removing Cover In Engine Compartment (Right Side)

6-cyl. 5V 3.0L engines
Remove cover - 1 - at right in engine compartment.
12:53:57 AM Page 37
Fig. 50: Removing Rear Engine Cover

Remove rear engine cover upward.
cardiagn.com
V8 4.2 gasoline engines
Engine (from above and below) and engine compartment: Visual inspection for leaks and damage
Perform visual check as follows:
 Remove engine --> Engine cover: Removing

 Check engine and engine compartment for leaks and damage.
 Check lines, hoses and connections on following systems for leaks, chafing, porosity and cracks:
 Fuel system
 Cooling and heating system
 Brake system
12:53:57 AM Page 38
 Perform visual inspection from below using same viewpoints as when vehicle was on lift and noise
insulation removed.
Hood safety catch: lubricating
cardiagn.com
Fig. 52: Identifying Lubrication Points On Hood Safety Catch
 Lubricate hood safety catch only on lubrication places indicated - arrows -.
 Lubricant: "G 052.778 A2"
Continuously Variable transmission (CVT) 01J: Changing ATF
 Continuously Variable (CVT) transmission 01J: Change ATF --> - 37 - AUTOMATIC

TRANSMISSION - CONTROLS, HOUSING
Engine oil: Drain/extract, replace oil filter
WARNING: Oil extraction not permitted with various engine types! See maintenance
table.
NOTE:  Perform oil change at operating temperature.
 Hazet tension band 2.71-1

 or
 Oil filter wrench 3417
12:53:57 AM Page 39
 Oil extractor V.A.G 1.82
Fig. 53: Identifying Oil Drain Adapter T 40057 (2.0 TFSI)

cardiagn.com
 Oil Drain Adapter T 40057 (2.0 TFSI)
4-cyl. gasoline engines --> 4-cyl. gasoline engines
4-cyl. TFSI engines --> 4-cyl. TFSI engines
6-cyl. 3.2L FSI gasoline engines --> 6-cyl. 3.2L FSI gasoline engines
8-cyl. 4.2L MPI gasoline engines --> 8-cyl. 4.2L MPI gasoline engines
8-cyl. 4.2L FSI gasoline engines, RS4 --> 8-cyl. 4.2L FSI gasoline engines, RS4
Fig. 54: Identifying Oil Filter

12:53:57 AM Page 40
 Loosen oil filter - arrow - using oil filter wrench 3417 or tension band Hazet 2.71-1.
 Remove oil filter.

 Observe installation note on oil filter.
 Open oil drain plug or extract engine oil.
 Clean oil filter sealing surface on engine.
 Lubricate rubber seal lightly with oil.
cardiagn.com
Fig. 55: Identifying Oil Filter Unit And Hoses
 Install new filter and tighten.
WARNING: After changing oil filter unit, check clearance of hoses - arrows - going
from oil cooler to adjacent components. Correct the position of the oil
cooler, if necessary.
 Install oil drain plug with new gasket.

 Fill up with engine oil, specifications --> Engine oil: Fill
NOTE:  Engines with turbocharger:

 After the engine oil and oil filter have been replaced, observe the following
when first starting the engine:
 As long as the oil pressure warning light in the instrument panel insert
flashes, the engine is only to run at idle. Do not touch the accelerator
pedal! Bumping the accelerator pedal can damage the turbocharger or
destroy it completely.
 The full oil pressure achieved and the engine can be accelerated only
when the warning light extinguishes
 Check for cleanliness.
12:53:57 AM Page 41
4-cyl. TFSI engines
 Remove noise insulation --> Noise insulation: Removing
NOTE:  Before removing oil filter, motor oil must be drained from filter so that it
does not drain onto engine and attached parts.
cardiagn.com
Fig. 56: Identifying Valve Protection Cap And Oil Filter Housing Bottom
 Remove bottom valve protective cap - 1 -.

 Remove ball head hose from Oil Drain Adapter T 40057 and turn threaded bolt in bottom oil filter
housing bottom valve - 2 - under a slight resistance is felt.
 Now place ball head hose on threaded bolts and turn Oil Drain Adapter T 40057 to stop - a clear snap of
the drain valve will be heard.
 Allow oil filter to run empty.
WARNING: Hot engine oil
 Open oil drain plug or extract engine oil.
12:53:57 AM Page 42
Fig. 57: Identifying Remove Oil Drain Adapter T 40057

 Remove Oil Drain Adapter T 40057.
cardiagn.com
 Check whether bottom valve - 1 - is flush and not crooked, as in illustration (A02.0423).
 Remove protective cap.
 Open oil filter housing - 2 - with Oil Filter Wrench 3417 or with socket AF 36, e.g. Socket AF 36 T10125
and remove oil filter.
Fig. 58: Identifying Filter Insert And Gasket

 Replace filter insert - 4 - and gasket - 3 -.

 Note position of service flag on sealing ring (see arrow)
12:53:57 AM Page 43
 Clean sealing surface on oil filter housing.

 Smooth side of sealing ring must face toward outside
 Screw on filter housing and tighten.
 Install oil drain plug with new gasket.
 Fill up with engine oil, specifications --> Engine oil: Fill

cardiagn.com
6-cyl. 3.2L FSI gasoline engines
NOTE:  Loosen the cap before draining / extracting, so that the engine oil can run
out of the oil filter housing.
Fig. 59: Identifying Coolant Reservoir And Oil Filter Cover

 Remove coolant reservoir - 1 - and lay aside.

 Remove oil filter cover with socket wrench SW 36 - 2 -.
 Clean sealing surfaces oil filter cover and at oil filter housing.
 Replace oil filter insert..
12:53:57 AM Page 44
Fig. 60: Identifying Sealing Ring On Cap

Sealing ring on cap, replacing
cardiagn.com
 Remove sealing ring at pull tab - arrow A - from cap - 1 -.
 Insert new sealing ring - 2 - with semicircular profile in groove - arrow B - on cap.
 The pull tab - arrow A - must face upward.

 Smooth side of sealing ring - 2 - must face toward outside
Fig. 61: Identifying Oil Filter Housing O-Ring

O-ring, inserting in oil filter housing
 Insert O-ring - 2 - in groove - arrow - on oil filter housing - 1 -.

 Engage new oil filter insert in oil filter cover.
 Install oil filter cover.
12:53:57 AM Page 45
 Install coolant reservoir.

 Remove noise insulation
 Open oil drain plug on oil pan or extract engine oil.
 Install oil drain plug.
NOTE:  Oil drain plug is installed without seal.

 Fill motor oil. --> Engine oil: Fill
8-cyl. 4.2L MPI gasoline engines
 Remove engine cover upward.
cardiagn.com
Fig. 62: Identifying Oil Filter Cover
 Remove oil filter cover - arrow - using socket wrench SW24.

 Filter element, removing
NOTE:  Removing the filter element will open a valve and oil in the filter housing
will flow automatically into the crankshaft housing.
12:53:57 AM Page 46
cardiagn.com
Fig. 63: Identifying O-Ring And Oil Filter Insert
 Replace O-ring - 2 - as well as oil filter insert - 3 -.

 Tighten cover - arrow -.

NOTE:  Check for cleanliness.
8-cyl. 4.2L FSI gasoline engines, RS4
12:53:57 AM Page 47
Fig. 65: Identifying Screws And Line

cardiagn.com
 Loosen screws - 1 - and unclip line - 2 -.
 Lay aside bracket.


12:53:57 AM Page 48
cardiagn.com


 Open oil drain plug and drain engine oil.

 Do not extract engine oil!
12:53:57 AM Page 49
Navigation: Eject button, unlocking
cardiagn.com
(DLC)

 Guided functions
 Service work
 J401 - Navigation, Eject button, locking/unlocking

Test drive: Perform
To what extent the following can be checked is dependent upon the vehicle equipment and local conditions
(urban/country).
 The following should be checked by means of a road test:
 Engine: Output, misfiring, idling speed, acceleration

 Clutch: Pulling away, pedal pressure, odors
 Gear selection: Ease of operation, shift lever position
 Automatic transmission: Selector lever position, shift lock / ignition key removal lock, shift behavior,
12:53:57 AM Page 50
instrument panel insert display
 Foot and parking brake: Function, free travel and effectiveness, pulling to one side, juddering, squeal
 ABS function: When braking with activated ABS, the brake pedal must pulse noticeably.
 Steering: Function, steering free play, steering wheel centralized when wheels are in straight ahead
position
 Tilt/slide sunroof: Function
 Cruise Control System (CCS): Function

 Radio: reception, SCV, interference
 Driver Information System (DIS): Functions
 A/C system: Function
 Vehicle: Moving off line when traveling straight ahead (level road)
cardiagn.com
 Imbalance: Wheels, drive shafts
 Wheel bearings: Noises
 Engine: Hot starting behavior
Radio: Activate anti-theft coding by entering security code
Radio units are shipped with a fixed code. Fixed code means that every radio unit with anti-theft coding has
been programmed with its own code. This code is not active from the factory. To increase anti-theft protection,
there is no longer a radio card in the radio and navigation system owners manual. The entry of the radio code is
no longer described in the owners manual.
The Anti-theft coding on a unit that is ready to play is activated by entering the fixed code.
On chorus II+, concert II+ and symphony II+ radio systems, enter the radio code as follows
 Switch on radio. "Code 1000" appears in the display.

 Press upper left control button "X___" -arrow- until first digit of radio code appears in display.
 Enter remaining three radio code digits with other three control buttons
 Press "ENTER" control button. The radio is coded.
12:53:57 AM Page 51
Fig. 70: Identifying Radio Controls

 Dispose of sticker with radio code.
cardiagn.com
If the radio code is entered incorrectly two times and "Code Safe 2" appeared in the display, use the following
procedure
Leave radio switched on approx. 60 minutes. After 60 min., "Code Safe / Code 1000" appears in the display and
the radio is switched off
Enter radio code again.
On navigation system BNS 5.0, enter radio code as follows
 Switch on navigation system

 Enter PIN using Speller
 Confirm entry with "OK"
NOTE:  Please inform the customer that he can only learn the anti-theft radio code
from the service advisor
 That way, thieves really cannot use the radio!
Radio/navigation system Plus (Chorus, Concert, Symphony): Deactivating transport mode
Transport mode can be activated in "Instrument cluster 17" and in "Radio 56".
 Deactivating transport modes, e.g. in instrument cluster 17, is described as follows.
Deactivating for Radio 50 is the same procedure
 Connect Vehicle Diagnosis, Testing and Information System VAS 5051 --> DTC memory: Retrieving
12:53:58 AM Page 52
with VAS 5051/ 5052
Fig. 71: Identifying Vehicle Self-Diagnosis Button On Scan Tool Display
cardiagn.com
Indicated on display:
Select mode of operation:
 Press button for "Vehicle Self-Diagnosis" on display.
NOTE:  If the indications shown in the work procedure are not indicated on the
display: User manual for VAS 5051 tester
Fig. 72: Identifying Selection Screen On Scan Tool

Select vehicle system:
12:53:58 AM Page 53
 Press "17 - Instrument panel insert" on display - arrow -.
Fig. 73: Diagnosis System Display

cardiagn.com
Control module identification and the coding will be displayed - arrow -.
 Press the arrow button - 1 - on the screen display.
Fig. 74: Diagnosis System Display

 Press "10 - Adaptation" on display - arrow -.
12:53:58 AM Page 54
Fig. 75: Diagnosis System Display: Displayed Number Block

cardiagn.com
 Press button 9 twice on number block display - arrow -.
Transport mode is activated or deactivated in adaptation channel 99.
 Confirm entry with Q button on display number block.
NOTE:  "0" Transport mode not active

 "1" Transport mode active
Fig. 76: Identifying Diagnosis System Display Functions

 Drag the cursor - arrow - on the display to the left, until 0 is indicated above the scroll bar - 1 -.
 0 Transport mode not active
12:53:58 AM Page 55
 Press the "Save" button - 2 - on display.
Fig. 77: Identifying Diagnosis System Display

cardiagn.com
 Press the "Accept" button - arrow - on display.
End procedure
Fig. 78: Identifying "Go To" Button On Scan Tool Display

 Press the "Go to" button - arrow - on display.
12:53:58 AM Page 56
Fig. 79: Identifying "Exit" Button On Scan Tool Display

cardiagn.com
 Press "exit" button - arrow - on display.
 Press "exit" button in exit menu.
 Turn off ignition.
NOTE:  VAS 5051 must remain connected for additional tests and possibly for
emissions testing.
Tire repair kit: Checking
Fig. 80: Identifying Durability Date In Tire Repair Kit

On vehicles with a tire repair kit, check durability date - arrow -.
NOTE:  If expiration date has passed, replace bottle.
Wheel bolts: Tighten to correct torque setting
12:53:58 AM Page 57
Center cap
Fig. 81: Identifying Removal Hook

cardiagn.com
The removal hook - A - for removing the center cap is located in the vehicles tool kit.
Wheel bolts
The adapter to loosen/tighten the anti-theft wheel bolts is located with the vehicle tool kit.
NOTE:  Be sure to tighten wheel bolts in diagonal sequence to the following

specified torque:
 Place adapter with vehicle tool kit after completing work.
Correct wheel installation
 When installing wheels, you must observe the following points to ensure wheels fit securely:
 Always tighten wheel bolts to the specified torque so the wheel bolt seats in rim are not deformed.
 When installing a wheel, do not tighten first wheel bolt immediately (for example, with an impact
wrench). This would prevent other bolts from centering rim properly when they are screwed in. Rim
could then become loose, even if tightened to specified torque.
 Before installing wheels, check for rust/corrosion in wheel bolt seats and contact surfaces between rims
and hubs, removing if necessary. Otherwise, the wheel bolts can lose tension after installation and the rim
can come loose.
WARNING:  If the above points are not observed, wheels can come loose and the
wheel bolt seats in rim can be deformed.
 The deformity could be so small that you can't see it.
 But even small deformities in the wheel bolt seats can prevent the
wheel from fitting securely, so that it becomes looser and looser.
12:53:58 AM Page 58
Windshield washer system: Checking nozzle setting, adjusting nozzles if necessary
Fig. 82: Identifying Adjustment Tool T10127 Equipped With Needle 3125/ 5 A
cardiagn.com
Necessary special tools
 Windshield washer aiming tool T10127 equipped with replacement tip 3.25/5A
NOTE:  Never use a needle or a similar object, since it may damage the water
hoses in the spray nozzle!
Windshield spray jet setting
 Mark four points on windshield using water-soluble pen.
Fig. 83: Identifying Windshield Dimensions

Adjusting dimension:
 Dimension - a - = 2.0 to 2.5 mm

 Dimension - b - = 465 to 490 mm
12:53:58 AM Page 59
 Dimension - c - = 2.0 to 415 mm

 Dimension - d - = 140 to 2.5 mm
NOTE:  Adjusting dimensions are calculated from outer edge of windshield.

 Locate individual spray jet points using windshield washer aiming tool
T10127 with replacement tip 3.25/5A..
NOTE:  If the spray field is uneven or does not adjust to the aforementioned
specifications, replace the washer jet (repair measures).
Rear window spray jet setting
cardiagn.com
Fig. 84: Identifying Windshield Wiper Dimensions
 Adjust spray nozzle with windshield washer aiming tool T10127 so that washer fluid sprays onto areas
shown on rear window above wiper.
 Dimension - a - = approx. 125 mm

 Dimension - b - = approx. 2.5 mm
 Dimension - c - = approx. 5 mm
Washer jet adjustment, front window (Cabriolet)
12:53:58 AM Page 60

cardiagn.com
 Dimension - a - = 3.0 mm
 Dimension - b - = 500 mm
 Dimension - c - = 450 mm
 Dimension - d - = 2.0 mm
NOTE:  The adjustment dimensions are figured from the aluminum edge on the
trim.
T10127 with replacement tip 3.25/5A..
Service display: Resetting or adapting
NOTE:  Service display serves to remind the driver of service needed. The display
appears in the center display.
 Service indicators appears 1 month or 2.000 km before reaching service
interval. It disappears after 100 km. Example display: After a total driving
distance of 28,700 km, "SERVICE IN 13.0 KM" appears.
12:53:58 AM Page 61
Fig. 86: Identifying Service Display

 The distance remaining to the service interval can be viewed via the center
cardiagn.com
display menu by press button - 1 - once.
 When a service interval arrives, the text information appears in the center
display for 5 seconds after switching ignition on. It is shown after
automatic transmission message and a possible navigation system
destination. Display: "SERVICE!".
Service display, resetting
(DLC)
12:53:58 AM Page 62

 Service work
 Combination Processor, reset WIV

 WIV = Wartungsintervall - Verlngerung (Maintenance Interval Extension)
Oil quality, adapting
cardiagn.com
(DLC)

 Service work
12:53:58 AM Page 63
 Combination Processor, changing oil quality

NOTE:  It is necessary to change oil quality if changed between inspection or

Long Life Service.
 Inspection Service = Oil quality 1
 Long Life Service = Oil quality 2
 WIV = Wartungsintervall - Verlngerung (Maintenance Interval Extension)
 Please follow guided program function description
Maximum values, adapting
cardiagn.com
(DLC)

 Service work
 Combination Processor, adjusting maximum WIV value
12:53:58 AM Page 64
Fixed interval maximum values
NOTE:  WIV = Wartungsintervall - Verlngerung (Maintenance Interval Extension)

Service display, resetting without VAS 5051/5052
NOTE:  If reset without VAS 5051 or VAS 5052 , service display is automatically set
to fixed interval (15,000 km).
Resetting can be carried out using tester VAS 5051 or VAS 5052 in "Adaptation" function --> Service display:
Resetting or adapting
Service display can also be reset using the following procedure:
cardiagn.com

 Press Taste button - 1 - and switch on ignition at the same time.
After releasing button, display shows: "SERVICE IN ????Km" or "SERVICE!".
 Hold down button Taste - 2 - until text is reset to "SERVICE IN ????Km" or "SERVICE!".
Headlamp washer system: Check spray jet setting.
Headlamp cleaner spray jets are set at the factory and do not need to be adjusted.
Front axle joints: Seal boots, checking play and secure fit.
12:53:58 AM Page 65
NOTE:  Perform this test with vehicle on lift (wheels hanging freely).
Tie rod ends
 Check play by moving tie rods and wheels.
 You should not feel or see any play.
 Check all around ball joint boots - arrow - for damage and correct seating. Use a mirror, if necessary.
 Ball joint boots can usually be recognized by leaking lubrication.
cardiagn.com
Fig. 91: Identifying Lock Nut
 Make sure lock nut - 1 - is tightened to 40 Nm.
All control arms
12:53:58 AM Page 66
cardiagn.com
Fig. 92: Identifying Ball Joint Boots
 Check all around ball joint boots - arrows - for damage and correct seating. Use a mirror, if necessary.

Control arm
Fig. 93: Identifying Bearing Housing And Control Arm

 With unloaded wheels, check relative movement of wheel bearing housing to control arm.
 By raising and lowering the wheels several times by hand - arrow - the relative movement between
wheel bearing housing and control arm can be observed.
 If relative movement when lifting or lowering gives evidence of play that can be felt or seen, control arm
12:53:59 AM Page 67
must be replaced.
Drive shaft boot
 Check all around interior and exterior drive shaft boot for damage and correct seating. Turn wheel, if
necessary.
 By turning the front wheels, tears can be found in their early stages.
 Drive shaft boot damage can usually be recognized by leaking lubrication.
Windshield wiper blades: Checking park position (Cabriolet)
 Switch windshield wipers on and off and allow to run to end position.
cardiagn.com
Fig. 94: Checking Windshield Wiper Blade Tips Position
 Check whether wiper blades rest again front window in indicated position.
NOTE:  Dimensions indicate distance of wiper blades to plenum chamber cowl

panel grille on lower window edge.
 If necessary, unscrew wiper arm, align and tighten nuts.
 Activate mist wipe and check adjustment.
Headlamps: Check setting, adjust if necessary
The following test- and adjustment instructions are applicable to all countries. National guidelines or
regulations of the country must be observed.
Check and adjustment conditions
 Tire pressure OK.

 Lenses must not be damaged or dirty.
 Reflectors and bulbs OK.
12:53:59 AM Page 68
 Vehicle must be properly loaded.
Load: Vehicle must be loaded with one person on the drivers seat, weighing 75 kg, otherwise vehicle must be
empty (curb weight).
The curb weight is the weight of the vehicle ready for operation with completely filled fuel tank (at least 90%),
including the weight of all equipment items carried for operation (e.g. spare wheel, tool, vehicle jack, fire
extinguisher etc.).
If the fuel tank is not at least 90% full, adjust the weight as follows:
 Read fuel level from fuel gauge. Calculate additional weight needed using the following table. Place extra
weight in luggage compartment.
Tank filling table
cardiagn.com
Example:
If the fuel tank is half full, place a weight of 35 kg in the luggage compartment.
NOTE:  For additional weight use containers filled with water. A container filled
with 5 liters of water weighs approx. 5kg.
Vehicle must be rolled for several meters or the front and rear suspension must be bounced several times so that
the springs settle.
 Vehicle and headlamp adjuster must be on a level surface operating instructions for headlamp adjuster.
 Vehicle and headlamp adjuster must be aligned.
Ensure headlight adjuster is about 30 cm in front of headlight.
 Inclination must be set.
Inclination measurements are stamped in "%" at top of headlamp. The headlamps must be adjusted according to
these measurements. Percentage information is based on a projection distance of 10 meters. For example:
inclination of 1.0 % converts to approx. 10 cm.
Vehicles with manual headlight range adjuster:
 The headlight range adjuster thumb wheel must be in basic setting - 0 -.
Vehicles with automatic headlight range adjusting
NOTE:  To check/adjust headlights, they must always be placed in the basic

setting with the VAS 5051.
12:53:59 AM Page 69
 Performing basic setting with VAS 5051 :

 connect VAS 5051 with ignition switched off.
cardiagn.com
(DLC)
 Use K-lead adapter VAS 6017B.

 Select "Guided Fault Finding"
Enter vehicle information; all control modules are interrogated.
 Press the following selections in the order shown:
 Go To
 Functions and component selection
 Body
 Electrical Equipment
 01 - On Board Diagnostic (OBD) capable systems

 55-Dynamic Headlamp Range Control
 J 431-Dynamic Headlamp Range Control, Functions
 J 431-Headlamp Range Control Module, basic setting
 Press button
12:53:59 AM Page 70
Follow the steps of the tester and confirm the entry until the following text appears:
J 431-Headlamp Range Control Module, basic setting
 Press button
 Follow test sequence
Headlamps, checking adjustment (with new test screen without 15 setting line)
 Switch ignition and low beams on
cardiagn.com
Fig. 96: Identifying Headlight Setting Line, Break-Away Point & Center Point
 Horizontal light-dark border must contact hyphenated line - 1 - on test surface.

 Break-away point - 2 - between left horizontal part and rising part on right of light-dark border must run
vertically through central point - 3 -. The bright core of the light beam must be on the right of the vertical
line.
NOTE:  To make it easier to find break-away point - 2 - cover and uncover left half
of headlamp (as viewed when looking forward) a few times. Next, check
low beam again.
 After correct adjustment of dipped beams the center point of the main
beam must lie on the center mark - 3 -.
 For the previous test screen with 15 -setting line, adjust as for new test
screen. To avoid incorrect settings, ignore 15 setting line.
 If headlight adjustment is not OK: Adjust headlights:
Headlamps, adjusting
12:53:59 AM Page 71
Fig. 97: Identifying Adjustment Screws For Main Headlight (Right)

Main headlight (right)
cardiagn.com
Adjusting screw on right headlight:
Placement on left headlight is similar.
 To adjust height, turn adjustment screws - 1 - and - 2 - with same number of revolutions.
 To adjust laterally, turn only adjustment screw - 2 -.
Fog lights:
Inclination figures:
 Fog lights 20 cm
Fig. 98: Checking Whether Upper Light-Dark Border Touches Adjusting Line And Runs Across Entire
Test Screen Width Horizontally
 Check whether upper light-dark border touches adjusting line and runs across entire test screen width
horizontally.
12:53:59 AM Page 72
Fig. 99: Identifying Air Duct Grille, Bumper, And Adjustment Screw
 Remove air duct grille on inner side of bumper - arrow -.
cardiagn.com
 To change lamp range, turn adjustment screw - arrow -. Lateral adjustment is not possible.
NOTE:  Right fog light is shown in illustration. Adjusting screw on left fog light is
arranged symmetrically.
Other additional headlamps:
Accessory auxiliary headlamp systems must be checked and adjusted according to the guidelines valid for them.
Vehicle Electrical System Control Module - J519: coding
 Connect VAS 5051 --> DTC memory: Retrieving with VAS 5051/ 5052
 Go To
 Body
 01 On Board Diagnostic (OBD) capable systems

 Electrical system (Highline or Lowline depending on vehicle equipment)
 Electrical system function
 J519 Vehicle Electrical System Control Module, coding
 Press button
12:53:59 AM Page 73
Follow tester steps and confirm entry until following text appears:
OK J519 Vehicle Electrical System Control Module, coding
 Go To
 End
Dust and pollen filter: Replacing
NOTE:  Filter insert is available in different versions (with and without activated
charcoal insert as integrated odor filter).
 The filter is located beneath the fresh air plenum cover on the right side.
 Remove plenum chamber cover --> Plenum chamber cover: Removing
cardiagn.com
Fig. 100: Identifying Plenum Chamber Cover
 Unclip cover - B - and remove forward.

 Remove dust and pollen filter - C - from housing.
NOTE:  When inserting filter in filter frame, observe flow-through direction "arrow"
-D-
 When installing, ensure cover - B - is seated correctly. It must be clipped
in at both catches - A - , otherwise water will run on dust and pollen filter
and into A/C unit.
Manual transmission/final drive: Check oil level, add oil if necessary
--> -
 34 MANUAL TRANSMISSION - CONTROLS, HOUSING for 5 SPD. MANUAL TRANSMISSION
12:53:59 AM Page 74
012/01W FRONT WHEEL DRIVE

01E ALL WHEEL DRIVE
 34 - CONTROLS, HOUSING for 6 SPD. MANUAL TRANSMISSION 0A3 ALL WHEEL DRIVE,
INTERNAL COMPONENT SERVICING
 34 CONTROLS, HOUSING for 6-SPEED MANUAL TRANSMISSION 01X, FRONT-WHEEL
DRIVE
 34 CONTROLS, HOUSING for 6-SPEED MANUAL TRANSMISSION 02X, FOUR-WHEEL DRIVE
 34 CONTROLS, HOUSING for 6-SPEED MANUAL TRANSMISSION 0A3, ALL WHEEL DRIVE
Windshield/headlamp wiper system: Filling with fluid
 Fill washer fluid fully.
NOTE: Always add a neutral pH window cleaner to washer fluid (freeze protection
cardiagn.com

in winter).
Door arrester and lock cylinder: Lubricate
Fig. 101: Identifying Greasing Points For Door Latches

 Grease door latches only at lubrication points shown -arrows-.
 Lubricate lock cylinder.
Telematics: Emergency battery, replacing
NOTE:  Emergency battery should be replaced very 4 years on vehicles with
12:53:59 AM Page 75
Telematics.
Telematics control module is located in right footwell E-box (passenger side, below floor covering).
 Lower A-pillar trim, removing and installing; Floor covering, raising: --> - 70 - INTERIOR TRIM
cardiagn.com
Fig. 102: Identifying Passenger Side Electronics Box Cover
 Release passenger side electronics box cover - arrows -.

 Remove Telematics control module from E-box (do not disconnect control module).
Fig. 103: Identifying Screws On Bottom Side Of Telematics Control Module

 Remove both screws - arrows - on bottom side of Telematics control module and remove cover.
12:53:59 AM Page 76
Fig. 104: Identifying Connector And Emergency Battery

 Disconnect connector - 1 - and remove emergency battery - 2 -.
cardiagn.com
 Perform installation in reverse order of removal.
Note before disconnecting battery.
WARNING: Activate Telematics control module Service Mode before disconnecting

battery.
Vehicle Diagnostic, Testing and Information System VAS 5051; Guided Fault Finding; Adaptation;
Telephone/Telematics
NOTE:  Retrieve radio/navigation unit anti-theft coding before disconnecting

battery.
 If battery is reconnected, activate vehicle equipment (radio/navigation,
clock, electric windows, engine) according to operating instructions and
deactivate Telematics control module service mode. Vehicle Diagnostic,
Testing and Information System VAS 5051; Guided Fault Finding;
Adaptation; Telephone/Telematics
Transport protection: Remove front and rear strut transportation protection devices
12:53:59 AM Page 77
Fig. 105: Identification Tag Attached At Mirror

For some models the front and rear suspension struts have transportation protection devices installed. These
models can be identified by a tag attached at the mirror - arrow -.
cardiagn.com
 Release coil spring (for example, put vehicle on lift)
NOTE:  It is not necessary to remove the wheels.

 Be careful not to damage surface of coil springs.
Remove transportation protection devices --> Front strut
Front strut
Fig. 106: Identifying Auxiliary Strut, And Transportation Protection Devices

 Pull auxiliary strut - 2 - downward.

 Remove 2 transportation protection devices at each strut - 1 -.
 Install auxiliary strut - 2 - by sliding up in spring retainer.
Rear strut
12:53:59 AM Page 78

cardiagn.com
Underbody protection: Visual inspection for damage
 When inspecting visually, observe underbody, wheel housings and sills!
Anti-roll protection: Checking function (Cabriolet)
 Connect VAS 5051 --> DTC memory: Retrieving with VAS 5051/ 5052
 Go To
 Body
 Body work

 Airbag 8.4E
 Airbag 8.4E functions
 Airbag control module output diagnostic test
12:53:59 AM Page 79
 Follow guided program.
Plenum chamber cover: Removing
cardiagn.com
Fig. 108: Identifying Plenum Chamber Cover & Removing Rubber Seal
 Remove plenum chamber cover rubber seal in direction of arrow.

 Remove plenum chamber cover - 1 - forward.
Winter tires from factory
On vehicles that were delivered from factory with winter tires, check for correct pressure during delivery
inspection.
The excessive speed warning sticker should be placed in drivers field of vision.
Spark plugs: Replacing
 Spark plug wrench 3.22 B
Fig. 109: Placing Ignition Coil Puller T40039 On Top Most Thick Rib Of Ignition Coils
12:53:59 AM Page 80
 Ignition Coil Puller T40039
WARNING: Place Ignition Coil Puller T40039 on top rib - arrow - of ignition coil and
pull this from spark plug. Placing on bottom rib can cause damage.
NOTE:  Plug designation --> -

 28 IGNITION/GLOW PLUG SYSTEM for 1.8 LITER 4-CYL. 5V TURBO
FUEL INJECTION & IGNITION, ENGINE CODE(S): AMB
 28 - IGNITION/GLOW PLUG SYSTEM for 2.0 LITER 4-CYL. 4V TURBO
FUEL INJECTION IGNITION, ENGINE CODE(S): BPG, BWT
 28 IGNITION/GLOW PLUG SYSTEM for 3.0 LITER 6-CYL. 5V FUEL
INJECTION & IGNITION, ENGINE CODE(S): AVK, BGN
cardiagn.com
 28 - IGNITION SYSTEM for 3.2 V6 4V FUEL INJECTION IGNITION,
ENGINE CODE(S): BKH
 28 - IGNITION/GLOW PLUG SYSTEM for 4.2 LITER V8 4V FUEL
INJECTION AND IGNITION, ENGINE CODE(S): BNS
 28 IGNITION/GLOW PLUG SYSTEM for 4.2 LITER V8 5V FUEL
INJECTION AND IGNITION, ENGINE CODE(S): BHF
4-cyl. 1.8L 5V engines --> 4-cyl. 1.8L
4-cyl. 4V/5V 2.0L, 2.0L FSI and 2.0L TFSI engines --> 4-cyl. 2.0L FSI and 2.0L TFSI engines
6-cyl. 4V/5V 3.0L and 3.2L FSI engines --> 6-cyl. engines 3.0L and 3.2L FSI:
8-cyl. 4V/5V 4.2L MPI engines, --> 8-cyl. engines 4.2L MPI
8-cyl. 4V 4.2L FSI (RS4) engines, --> 8-cyl. engines 4.2L (RS4)
4-cyl. 1.8L
 Remove engine cover --> Engine cover: Removing

12:54:00 AM Page 81
Fig. 110: Identifying Connectors At Spark Plugs

 Remove connector - 1 - at spark plugs.
cardiagn.com
 Push connector - 1 - toward ignition coil, press on catch with hand and remove connector.
 Remove ignition coil from spark plug using Ignition Coil Puller T40039.
 Remove spark plugs using spark plug wrench 3.22 B.
 Install new spark plugs.
NOTE:  Push ignition coils by hand into intended resources in cylinder head
cover.
4-cyl. 2.0L FSI and 2.0L TFSI engines

 Remove engine cover (if present) --> Engine cover: Removing
Fig. 111: Identifying Bolts And Connectors

 Remove both bolts - 1 -.
12:54:00 AM Page 82
cover.
6-cyl. engines 3.0L and 3.2L FSI:

Right cylinder bank
cardiagn.com
 Remove upper part of air filter --> Air cleaner: Clean air filter housing and replace filter
Fig. 112: Identifying Bolts, Connector, And Ignition Coil


 Remove ignition coil - 3 - from spark plug using Ignition Coil Puller T40039.
cover.
Left cylinder bank
12:54:00 AM Page 83
Fig. 113: Removing Coolant Hoses

 Remove coolant reservoir -arrow-.
cardiagn.com
 Tie aside coolant reservoir with coolant hoses 1 to 3 connected.


cover.
8-cyl. engines 4.2L MPI
12:54:00 AM Page 84
Right cylinder bank
cardiagn.com

cover.
Left cylinder bank
Fig. 116: Removing Cover Upward

12:54:00 AM Page 85
 Remove cover upward.

cardiagn.com


cover.
8-cyl. engines 4.2L (RS4)
12:54:00 AM Page 86
Right cylinder bank
cardiagn.com

 Remove spark plugs using spark plug wrench T40039.
cover.
Left cylinder bank
12:54:00 AM Page 87

cardiagn.com

cover.
Headlights: Aiming using Hella Universal Beamsetter IV
Service
Align vehicle headlights using the Hella Universal Beamsetter IV VAS 5107 and the following procedure:
Additional instructions and diagrams Instruction Manual for the Hella Beamsetter Series IV
12:54:00 AM Page 88
Fig. 122: Identifying Floor Surface Specifications For Vehicle

 Position vehicle on a flat floor surface that meets the following (ISO 10640) specifications:
cardiagn.com
 0.5mm or less slant from front wheel to back wheel of the Hella Universal Beamsetter IV VAS 5107 - A -
.
 1mm or less slant per meter for the length of the vehicle - B -.
 Clean headlight lenses.

 Adjust vehicle tire pressure to specifications.
Have a second technician sit in the drivers seat while aligning the headlights.
 Bounce front and rear of vehicle up and down several times to settle vehicle suspension.
Setting low beam alignment of drivers side headlight
 Move Hella Universal Beamsetter IV VAS 5107 into position in front of the vehicle so it is aligned with
the vehicle and Hella Universal Beamsetter IV VAS 5107 is 30 to 70cm (12 to 28 in.) from the drivers
side headlight.
 Switch headlights ON in low beam position.
 Align Hella Universal Beamsetter IV VAS 5107 so it is centered on the headlight (align vertically then
horizontally).
NOTE:  Use the arrows on the Hella Universal Beamsetter IV VAS 5107 housing as
a guide.
 You may want to use a straight edge or tape measure, because alignment
must be within 3cm (1.2 in.) of the center of the headlight.
 Without moving the Hella Universal Beamsetter IV VAS 5107 , slide Broad-
band sight toward center of vehicle (Broad-band sight can also be moved
up and down for a better position).
12:54:00 AM Page 89
Use Broad-band sight to make final alignment of Hella Universal Beamsetter IV VAS 5107 to vehicle by:
 Loosening hand-wheel that locks column in place.

 Sighting down through the slit in the Broad-band sight and rotating Hella Universal Beamsetter IV VAS
5107 and column until two similar points on vehicle are aligned
NOTE:  Try using corners of the headlight housings or two screws that are the
same height and as far apart as possible on the vehicle.
 Carefully tighten hand wheel without changing Hella Universal Beamsetter
IV VAS 5107 position.
 Set Inclination to 1.0 %.
 Set Hella Universal Beamsetter IV VAS 5107 "Scaled wheel" to the proper
low beam inclination %.
 Adjust height (vertical) alignment first. Turn headlight height adjuster
cardiagn.com
screw to align the upper edge of the flat portion of the beam with the
center horizontal line of the grid on the Hella Universal Beamsetter IV VAS
5107 pattern screen.
NOTE:  VOL is the correct beam pattern for both right and left headlights.
Fig. 123: Identifying Specifications For Drivers Side Headlight Beam Angle
 Adjust lateral (horizontal) alignment of drivers side headlight so that the peak (highest point) of the
headlight beam pattern aligns with the right edge of the target box of the grid on the pattern screen (it
should match the VOL pattern shown on the Hella Universal Beamsetter IV VAS 5107 ).
NOTE:  If the height alignment changed, readjust.
Checking drivers side headlight high beam alignment
 Switch headlights ON in high beam position.
12:54:00 AM Page 90
 Realign Hella Universal Beamsetter IV VAS 5107 with the high beam headlight if necessary.
Fig. 124: Identifying Beamsetter "Scaled Wheel" At 0%

cardiagn.com
 Set Beamsetter "Scaled wheel" to 0%.
 Cover low beam lamp (use hand or small piece of cardboard) and check that the "hot spot" of high beam
pattern is centered on the square target box of the pattern screen.
NOTE:  High beam pattern is built into the reflector design and cannot be adjusted
separately.
If high beam pattern is way out of adjustment:
 Inspect for reflector damage.

 Replace reflector if needed.
NOTE:  Always align headlight in the low beam position.
Aligning fog lamp
 Switch fog lamps ON.

 Align Hella Universal Beamsetter IV VAS 5107 with fog lamp (make sure it is between 30 and 70cm
from the fog lamp lens).
12:54:00 AM Page 91
Fig. 125: Identifying Hella Universal Beamsetter IV VAS 5107 Scaled Wheel At 1.4%
 Set Hella Universal Beamsetter IV VAS 5107 scaled wheel to 1.4%.
cardiagn.com
Adjust fog lamp so the top of the beam pattern aligns with the centerline of the target grid on the beam pattern
screen.
Passengers side headlight, alignment
 Move Hella Universal Beamsetter IV VAS 5107 to the passenger side of the vehicle and follow the same
procedures to align the Hella Universal Beamsetter IV VAS 5107 to the headlamp.
 Align headlight low beam, check high beam and align fog lamp.
NOTE:  Make sure to reset the Hella Universal Beamsetter IV VAS 5107 "Scaled
wheel" to the proper setting each time you change from low beam to high
beam or to fog lamp.
 Ensure that headlights and vehicle body are clean and free of fingerprints.
RAPGARD, inspection: Removal and disposal
From my 2.02
Service
Within 48 Hours after arrival at Dealer:
Inspection
 Inspect RAPGARD for damage or peeling.
If RAPGARD is disturbed (dented, scratched, etc.):
 You must note the damage on the Carrier Delivery Receipt, including damage type, extent and location.
12:54:00 AM Page 92
Failure to note damage on the Carrier Delivery Receipt will result in non-payment of the repair.
NOTE:  RAPGARD must be removed from the vehicle no later than six months
after application. See sticker (location on vehicle body varies) for detailed
information.
Within 72 Hours prior to delivery to the Customer:
 Remove RAPGARD from vehicle.

 Wash vehicle exterior.
 Inspect paint surfaces, moldings and glass.
 Protect the paint surface of all new vehicles by applying 3M Perfect-It Paste Wax (3M Part No. 39526) or
equivalent.
Removal
cardiagn.com
 Vehicle must be at room temperature.
 The ideal body surface temperature for RAPGARD removal is 60F (15.5C) to 80F (26.6C).
If body surface temperatures are below 60F (15.5C) or above 80F (26.6C) then:
 Removal procedure should be performed indoors after surface temperatures have been allowed to
stabilize within the given range.
 Rinse vehicle thoroughly with water to remove surface dirt or dust and to help stabilize body surface
temperatures.
 Starting at the corners of each panel, carefully remove RAPGARD from vehicle.
RAPGARD, paint inspection after removal
 Inspect painted surfaces under one of the following lighting conditions:
 Indoors under fluorescent lighting.

 Outdoors under bright sunlight.
Important!
If any defects on the exterior have been identified (scratches, dings, dents and other types of body damage):
 Contact your Service Manager and arrange to repair defects immediately.
NOTE:  After removal of RAPGARD, some vehicles may exhibit temporary paint
discoloration or paint swelling (caused by trapped moisture under the
RAPGARD).
12:54:01 AM Page 93
 This temporary swelling is caused by the paint finish absorbing moisture

trapped under the RAPGARD film.
 This swelling will disappear with exposure to the sun or heat lamps within
2 - 3 hours. Severe Paint swelling may require 2 - 3 days to recover.
DO NOT buff or refinish paint for this condition!
Adhesive residue removal
WARNING: Always read and follow manufacturer Cautions and Warnings regarding
use of product.
If RAPGARD adhesive residue remains on paint finish, remove with a non-abrasive polishing product such as,
(3M Part No. 59.5) light colors or (3M Part No. 5996) dark colors or equivalent.
cardiagn.com
Thick lines of adhesive residue can be removed with general purpose adhesive cleaner (3M Part No. 08987-
aerosol, or Part No, 08984-qt. can) or equivalent.
NOTE:  Paint discoloration (looks like shaded or dark magic marker lines) can be
removed with a heat gun using the following procedure:
 Hold heat gun approximately 3 in. away from affected paint surfaces and
apply heat using slow oscillating motions until discoloration is gone.
 If discoloration remains, wipe the heated area with Isopropyl alcohol and
repeat procedure to increase surface drying.
Important!
After inspecting and removing RAPGARD, washing vehicle, inspecting and repairing any defects in paint
surfaces, moldings and glass:
 Protect the vehicle paint surface by applying 3M Perfect-It Paste Wax (3M Part No. 39526) or equivalent.
RAPGARD Disposal
RAPGARD can be disposed as normal paper waste. If unsure about proper disposal procedures in your area,
check local regulations.
Tire Pressure Monitoring System: Programming tire pressures
Specified values should also be saved with every tire pressure adaptation, e.g. when vehicle load condition
changes, so that Tire Pressure Monitoring System can be as useful as possible. Do this as follows:
 Press Reset button on windshield washer lever.

 Select Tire Pressure Monitoring System.
12:54:01 AM Page 94
 Select Save tire pressures.
NOTE:  Saving of tire pressures must be started after each deliberate change to
specified values.
Timing belt: Replacing
4-cyl. 5V 1.8L Turbo engines
 Toothed belt, removing and installing --> -

 13 - ENGINE - CRANKSHAFT, CYLINDER BLOCK for 1.8 LITER 4-CYL. 5V TURBO
ENGINE MECHANICAL, ENGINE CODE(S): AMB
4-cyl. 2.0L 5V engines
cardiagn.com
 Toothed belt, removing and installing: --> -
ENGINE MECHANICAL, ENGINE CODE(S): AMB
ENGINE MECHANICAL, ENGINE CODE(S): BPG, BWT
4-cyl. 4V 2.0L FSI engines

4-cyl. 4V 2.0L TFSI engines

6-cyl. 5V engines 2.4L; 3.0L;

 13 ENGINE - CRANKSHAFT, CYLINDER BLOCK for 3.0 LITER 6-CYL. 5V ENGINE
MECHANICAL, ENGINE CODE(S): AVK, BGN
 13 - ENGINE - CRANKSHAFT, CYLINDER BLOCK for 3.2 V6 4V ENGINE
MECHANICAL, ENGINE CODE(S): BKH
Toothed belt change, filling out sticker - all
12:54:01 AM Page 95
Fig. 126: Locating Toothed Belt Change Sticker At Rear Of Engine Compartment
 Fill out toothed belt change sticker - 2 - at rear of engine compartment, attach new sticker if necessary.
cardiagn.com
TYPE PLATE / VEHICLE IDENTIFICATION NUMBER (VIN)
Type plate / Vehicle Identification Number (VIN)
Meaning of Vehicle Identification Number (VIN):
Vehicle data sticker
The vehicle data sticker is in the customers service schedule and in the vehicle in the spare wheel recess or on
the luggage compartment floor.
Fig. 127: Identifying Vehicle Data Sticker

Sticker contains the following vehicle data:
Engine code and engine identification
12:54:01 AM Page 96
NOTE:  The "engine code" is on the vehicle data sticker in the service schedule
and in the spare wheel recess or on the luggage compartment floor.
A sticker with "engine code" and "serial number" is also attached to toothed belt guard.
4-cyl. 5V 1.8L Turbo gasoline engine:
cardiagn.com
Fig. 128: Identifying Engine Number On Left Of Cylinder Block
Engine number ( "engine code" and "serial number" ) is located at left of cylinder block.
4-cyl. 5V 2.0L gasoline engine:

12:54:01 AM Page 97
4-cyl. 2.0L TFSI engine:
Fig. 130: Identifying Engine Number Stamped On Engine Block

cardiagn.com
Engine number ( "engine code" and "serial number" ) is stamped onto engine block - arrow -
V6 3.0 gasoline engines:
Fig. 131: Identifying Engine Code Stamped On Right Inner Side Of Cylinder Block
Engine number ( "engine code" and "serial number" ) is stamped on right inner side of cylinder block between
cylinder head and hydraulic pump.
12:54:01 AM Page 98
Fig. 132: Identifying Engine Number On Left Front Of Cylinder Block

Engine number ( "engine code" and "serial number" ) is located at left front of cylinder block - arrow -.
cardiagn.com
V8 gasoline engines:

VEHICLE LIFTING
Vehicle lifting
WARNING:  Vehicle may only be lifted at points indicated in illustration in order

to avoid damaging vehicle floor pan and to prevent vehicle from
tipping.
 Never start engine and engage a gear with vehicle lifted so long as
even one wheel has contact with the floor. There is a risk of an
accident if this is not observed!
 If work is to be performed under vehicle it must be supported by
12:54:01 AM Page 99
suitable stands.
Floor jack
Always use a suitable rubber or wooden block between the jack and the vehicle.
A floor jack must be attached only at the mounting points depicted in the illustration.
Do not lift the vehicle at the engine oil pan, transmission, or on front or rear axles as serious damage may result.
Workshop hoist
Before driving on to a lifting platform ensure there is sufficient clearance between low lying vehicle
components and lifting platform.
Lifting points for lifting platform and floor jack
cardiagn.com
Fig. 134: Identifying Front Side Member Vertical Stiffener
Front:
At side member vertical stiffener in area of marking for onboard vehicle jack.
12:54:01 AM Page 100

Fig. 135: Identifying Rear Side Member Vertical Stiffener

Rear:
TOW STARTING/TOWING
Tow starting/towing
 Attach tow rope or bar only at following eyes:
Front towing eye
cardiagn.com
Fig. 136: Identifying Front Towing Eye
 Remove cover from right bumper.

 Remove towing eye from vehicle tool kit compartment.
 Screw in towing eye until stop and tighten eye with wheel bolt wrench.
Rear towing eye
12:54:01 AM Page 101

Fig. 137: Identifying Rear Towing Eye

cardiagn.com
Remove towing eye after use and return to vehicle tool kit storage compartment. Towing eye must always be in
vehicle.
NOTE:  The tow-rope should be able to stretch to reduce the risk of damage to
both vehicles. It is advisable to use synthetic fiber ropes or ropes of
similar elastic material only. However, it is safer to use a tow-bar!
 Avoid excessive towing effort and do not jerk. During towing operations
on unsurfaced roads there is always a danger that the attachment points
will be overstressed and damaged.
 Vehicle towing should only be done if it is not possible to start the engine
with the starting assist cable.
If the vehicle must ever tow or be towed, observe the following:
 Regulations concerning towing must be observed.

 Both drivers must be familiar with the specifics of towing procedures. Inexperienced drivers should not
attempt to tow start or tow.
 When using a tow rope the driver of the towing vehicle must engage the clutch very gently when moving
off and changing gear.
 The driver of the vehicle being towed must ensure that the tow rope is always taut.
 The emergency lights must be switched on both vehicles - unless local regulations differ.
 The ignition must be switched on, so that the steering wheel is not locked and the turn signals, horn,
windshield wipers, and windshield washer system can be operated.
 Since the brake booster only works with the engine running, the brake pedal must be stepped on with
12:54:01 AM Page 102

substantially more force when the engine is switched off.

 With the engine switched off, the power steering also does not work, increasing the amount of steering
effort.
 Without lubricants in the manual transmission and/or automatic transmissions the car may only be towed
with raised drive wheels.
When towing vehicles with manual transmission, observe the following:
 Before tow starting, push in clutch pedal and hold, and select gear 2 or 3.
 When both vehicles are moving, release clutch pedal.
 As soon as engine starts, depress clutch and move gear stick into neutral to avoid running into the towing
vehicle.
cardiagn.com
NOTE:  Vehicles with catalytic converter (gasoline engine only) must not be
started when the catalytic converter is at operating temperature and
pulling the vehicle over a longer distance of more than 50 m. Otherwise
unburned fuel may pass into the catalytic converter and cause damage.
 Tow starting vehicles with an automatic transmission is for technical
reasons not possible.
When towing vehicles with front wheel drive and automatic transmission, observe the following:
 Selector lever must be in the "N" position.

 Do not tow vehicle faster than 50 km/h (30 mph).
 Do not tow further than 50 km (30 miles).
For longer distances, the front end of the vehicle must be raised.
Reason: When the engine is not running the transmission oil pump is not working and the transmission is not
adequately lubricated for high speeds or long distances.
Using a breakdown vehicle, the vehicle may only be towed suspended at the front.
Reason: If given a rear suspended tow, the drive shafts turn backward. This would cause the planetary gears in
the automatic transmission to achieve such high RPM that the transmission would be heavily damaged within a
very short time.
When towing vehicles with all wheel drive and manual transmission, also observe the following:

12:54:02 AM Page 103

Using a breakdown vehicle the vehicle may be towed suspended at front or rear.
NOTE:  If normal towing of the vehicle is not possible, the vehicle must be
transported with a special transporter or trailer. This is also valid for
distances greater than 50 km (30 miles).
When towing vehicles with all wheel drive and automatic transmission, also observe the following:

The vehicle must not be towed by a tow truck with front or rear axle raised.
NOTE:
cardiagn.com
 If normal towing of the vehicle is not possible, the vehicle must be
VEHICLE CHECKS WITHIN INSPECTION AND
Vehicle checks within inspection and service framework
For vehicle checks, we recommend interactive acceptance VAS 5000 and performance test stand V.A.G 1858.
Brake check
Information for checking brakes on front and all wheel drive vehicles is in the corresponding brake system
repair manual.
Performance check
Perform performance check on performance test stand recommended by Audi. The corresponding correction
factors for automatic transmissions and all wheel drive are provided in these test stands. Vehicles with all wheel
drive may only be tested on a four-wheel performance test stand. The four-wheel performance test stand V.A.G
1858 has movable rollers in order to be able to test vehicles with different axle spacing.
Tachometer check
With the tachometer test, the vehicle wheels are driven. Vehicles with all wheel drive may only be tested on a
four-wheel test stand.
Shock absorber check
Information on testing shock absorbers can be found in the suspension repair manual.
12:54:02 AM Page 104

Maintenance Maintenance Procedures
Maintenance
Maintenance Procedures
01 - MAINTENANCE
ENGINE OVERVIEW
NOTE:  Some engines listed below are applicable to European vehicles.
Gasoline engines
Engine code ALZ AVJ BFB ALT AWA BEX BKB BGB
Emissions EU IV EU IV EU IV EU IV EU IV EU IV EU III EU IV
category
cardiagn.com
Number of 4/2 4/5 4/5 4/5 4/4 4/5 4/5 4/4
cylinders/valves
per cylinder
Displacement L 1.6 1.8 1.8 2.0 2.0 1.8 1.8 2.0
Output kW 75/5600 110/5700 120/5700 96/5700 110/6000 140/5700 120/5700 147/5700
at
RPM
Torque Nm 148/3600 210/ 225/ 195/3300 200/3500 240/ 220/1750 280/2000 3
at 1750 ... 1950...4700 1980...5400
RPM 4600
Stroke mm 77.4 86.4 86.4 92.8 92.8 86.4 86.4 92.8
Bore mm 81.0 81.0 81.0 82.5 82.5 81.0 81.0 82.5
Compression ratio 10.3 9.3 9.5 10.3 11.5 9.5 9.5 10.5
Fuel Simos 3.4 ME 7.5 ME 7.1 ME 7 MED 7.1 MED 7.1 MED 7.1 TFSI
injection/Ignition Motronic Motronic Motronic Motronic Motronic Motronic Motronic
RON min. 95 95 95 95 98 98 95 98
(unleaded) (unleaded) (unleaded) (unleaded) (unleaded) (unleaded) (unleaded) (unleaded) (
1*) 1*) 1*) 1*) 2*) 2*) 1*) 2*)
Gasoline engines
Engine code BDV AMM ASN BBJ AUK BBK BNS

Emissions category EU IV EU IV EU IV EU IV EU IV EU IV EU IV
No. of cylinders 6 6 6 6 6 8 8
12:49:46 AM
12:49:56 Page 1
Valves per cylinder 5 5 5 5 4 5 4

Displacement L 2.4 2.4 3.0 3.0 3.2 4.2 4.2
Output kW at 125/6000 120/6000 162/6300 160/6300 188/6400 253/7000 309/7800
RPM
Torque Nm at 230/3200 230/3200 300/3200 300/3200 320/3400 410/3500 430/5500
RPM
Bore mm 81.0 81.0 82.5 82.5 84.5 84.5 84.5
Stroke mm 77.4 77.4 92.8 92.8 92.8 92.8 92.8
Compression ratio 10.5 10.5 10.5 10.5 12.5 11.0 12.5
Fuel injection/ Ignition Motronic Motronic Motronic Motronic FSI Motronic Motronic
system ME 7.1. ME 7.1. ME 7.1. ME 7.1. Motronic ME 7.1.1 MED 9.1
Hitachi
RON min. 95 95 98 98 98 98 98
(unleaded) (unleaded) (unleaded) (unleaded) (unleaded) (unleaded) (unleaded)
1*) 1*) 2*) 2*) 2*) 2*) 2*)
cardiagn.com
Diesel engines
Engine code AVB AWX, AVF AKE AYM, BFC BAU, BSG BPP BKN
BCZ, BDH
BDG
Emissions EU III EU III EU III AYM, EU III BAU EU EU IV EU IV EU IV
category BCZ EU III BDH
III BDG EU III +
EU III + D4
D4
Number of 4/2 4/2 6/4 6/4 6/4 6/4 6/4 6/4 6/4
cylinders/valves
per cylinder
Displacement L 1.9 1.9 2.5 2.5 2.5 2.5 2.7 2.7 3.0
Output kW 74/4000 96/4000 132/4000 114/4000 120/4000 132/4000 120/4000 132/4000 150/4000
at
RPM
Torque Nm 250/1900 * See footnote 370/ 310/ 310/ 370/ 380/ 380/ 450/
at 285/ 1500 ... 1500 ... 1400 - 1500... 1500- 1500- 1500-
RPM 1750 ...2750 2500 2500 3600 2500 3200 3200 3000
Bore mm 79.5 79.5 78,3 78,3 78,3 78,3 83.0 83.0 83.0
Stroke mm 95.5 95.5 86.4 86.4 86.4 86.4 83,1 83,1 91,5
Compression ratio 18.5 18.5 18.5 18.5 18.5 19.5 17.5:1 17.5:1 19.5
Fuel Diesel Diesel Diesel Diesel Diesel Diesel Diesel Diesel Diesel
12:49:47 AM Page 2
injection/Ignition (direct (direct (direct (direct (direct (direct (direct (direct (direct
injection) injection) injection) injection) injection) injection) injection) injection) injection
CZ min. 51 51 51 51 51 51 51 51 51
* Engine code AVF 310 Nm
Diesel engines
Engine code BKE BLB BNA BPW BRC BRF BVF BRD BRE B
Emissions EU IV EU IV EU IV EU IV EU IV EU IV EU IV EU IV EU IV E
category
Number of 4/2 4/4 4/4 4/2 4/2 4/4 4/4 4/4 4/4
cylinders/valves
per cylinder
Displacement 1.9 2.0 2.0 2.0 2.0 2.0 2.0 2.0 2.0
cardiagn.com
Output kW/rpm 85/4000 103/4000 100/4000 103/4000 100/4000 100/4000 93/4000 125/4000 103/4000 89
Torque 285/1900 320/ 320/ 320/ 320/ 320/ 320/ 350/ 320/ 320
1750- 1750- 1750- 1750- 1750- 1750- 1750- 1750- 2
2500 2500 2500 2500 2500 2500 2500 2500
Bore 79.5 81.0 81.0 81.0 81.0 81.0 81.0 81.0 81.0 8
Stroke 95.5 95.5 95.5 95.5 95.5 95.5 95.5 95.5 95.5 9
Compression 19,0 18.5 18.5 18.5 18.5 18.5 18.5 18.5 18.5 1
ratio
Fuel Diesel Diesel Diesel Diesel Diesel Diesel Diesel Diesel Diesel D
injection/Ignition (direct (direct (direct (direct (direct (direct (direct (direct (direct (d
injection) injection) injection) injection) injection) injection) injection) injection) injection) inje
Diesel particle - - - X X X X X X Inst
filter po
CZ min. 51 51 51 51 51 51 51 51 51
Gasoline engines
Code letters BPG BWT

Displacement ltr. 1.984 1.984
Output kW at 1/rpm 147/5700 147/5700
Torque Nm at rpm 280/2000 280/1800
Bore Dia. mm 82.5 82.5
Stroke mm 92.8 92.8
Compression ratio 10.5 10,5
RON 98 1) 98 1)
Fuel injection and ignition system FSI FSI
Ignition sequence 1-3-4-2 1-3-4-2
Knock control yes yes
12:49:47 AM Page 3
Charging yes yes

Exhaust gas recirculation no no
Variable intake manifold no no
Variable valve timing yes yes
Secondary air injection (AIR) no no
 1) Unleaded RON 95 is also permissible, although with reduced power.
DELIVERY INSPECTION
Delivery inspection
--> ServiceNet; Delivery Satisfaction Program; Perfect Delivery Inspection (PDI) Checklists for
appropriate model and year
OIL CHANGE SERVICE
cardiagn.com
Oil change service
For engine oil specifications and capacities please refer to --> Fluid Capacity Chart for appropriate
model and year
Also, for appropriate service intervals refer to --> ServiceNet; Maintenance Schedule for appropriate
model year
INSPECTION SERVICE
Inspection service
--> ServiceNet; Delivery Satisfaction Program; Perfect Delivery Inspection (PDI) Checklists for
appropriate model and year
Also, for appropriate service intervals refer to --> ServiceNet; Maintenance Schedule for appropriate
model year
DESCRIPTION OF WORK
All switches, all electrical components, all displays and other operating elements: Checking function
 Check following:
 Lighting, headlamps, fog lights, turn signals, hazard warning flashers, taillights, rear fog lights, backup
lights, brake lights, parking lights
 Interior and reading lights (automatic shutoff on interior lights), illuminated storage compartment,
illuminated ashtray, luggage compartment lighting, illuminated ignition
 Warning buzzer for lights and/or radio left on
12:49:47 AM Page 4
 All switches in console
 Driver Information System (DIS)

 Instrument unit with all displays, meters and lights
 Two-tone horn
 Windshield/headlamp wipers, headlamp cleaning system
 Cigarette lighter
 Electric exterior mirrors (heated, adjustable)
 Electric windows
 Electric tilt/slide sunroof
 Central locking, remote control operation, comfort closing

 Electric seat
cardiagn.com
 Heated seat
 Radio
Final drive (automatic transmission): Check oil level, add oil if necessary
Automatic transmission
--> -
 39 - FINAL DRIVE, DIFFERENTIAL for 5 SPD. AUTOMATIC TRANSMISSION 01V

 39 FINAL DRIVE - FRONT DIFFERENTIAL for 6 SPD. AUTOMATIC TRANSMISSION 09L ALL
WHEEL DRIVE
Continuously Variable Transmission (CVT) transmission
--> - 39 - FINAL DRIVE, DIFFERENTIAL
Battery: Check
Battery with "magic eye"
Battery is located in plenum chamber between engine compartment and windshield or in spare wheel well on
RS4.
12:49:47 AM Page 5
Fig. 1: Pushing Cover Over Battery Toward Right And Removing It Upward
 Slide cover over battery to right - arrow 1 - and remove upward - arrow 2 -.
cardiagn.com
 The visual indicator - arrow - gives information about electrolyte level and battery charge.
12:49:47 AM Page 6

 Check electrolyte level at visual indicator - arrow -.

 Tap lightly on battery housing with a blunt object, air bubbles under the visual indicator can cause a false
reading.
 Green --> battery charge is OK.
 Black --> no charge or charge too low
 No color or yellow --> critical electrolyte level has been reached, battery must be replaced --> - 27
BATTERY, STARTER, GENERATOR, CRUISE CONTROL

battery..
cardiagn.com
Battery sealing plugs
 On batteries with visible min and max markings, electrolyte level only needs to be checked visually.
 Electrolyte level must be between min. and max. markings.
 On batteries where the outer min. and max. markings are difficult to see or the visibility of the electrolyte
level cannot be guaranteed due to the opaque battery housing, the sealing plugs must be removed. Then it
is possible to check electrolyte level by a visual inspection of the battery interior.
 The electrolyte level must meet the inner electrolyte level marking (plastic bar). This corresponds to the
outer max. mark.
NOTE:  If electrolyte level is too low, battery loses capacity (loses performance)
because the cell plates dry out. If the cell plates are not covered by
electrolyte, the plates and plate bridges start to corrode causing the
function of the battery to diminish. After a while the battery does no longer
function. The battery becomes useless.
WARNING: If the electrolyte level is below them in. marking, the battery must be
replaced! --> - 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL
Valve-regulated lead acid battery or absorbed glass mat (AGM) battery
NOTE:  Valve-regulated lead acid or AGM batteries are sealed, they cannot and
must not be opened. --> - 27 BATTERY, STARTER, GENERATOR, CRUISE
CONTROL
Battery: No load voltage, checking before starting engine for the first time
Necessary test equipment
12:49:47 AM Page 7
 Digital multimeter V.A.G 1715
or
 Portable multimeter V.A.G 1526 B
cardiagn.com
Fig. 4: Special Tool - Multimeter V.A.G 1526 A
Portable multimeter
NOTE:  Battery must not be loaded by connected components for at least 12 hours
before testing.
 Battery must not be charged for at least 12 hours before testing.
 Measure voltage between terminals with engine switched off.
WARNING: Always follow procedure exactly, otherwise measured values could be

incorrect.
Battery: Ensure battery cable fits securely
12:49:47 AM Page 8
 Check battery terminals on vehicle battery for secure fit, tighten nuts on -terminal -1- and + terminal - 2 -
if necessary.
WARNING: If the battery clamp is not seated securely on the positive terminal,
disconnect battery Ground (GND) strap on battery negative terminal first,
to prevent possible accidents.

battery..
cardiagn.com
 Check battery for secure fit, tighten screws - 4 - on securing bracket - 3 - if necessary.
Tightening torque Nm
Battery connection to battery terminal 6
Screw to securing bracket 12
Battery: Perform battery load test
Battery load test indicates battery condition.
12:49:47 AM Page 9
Fig. 7: Battery VAS Tester

 Battery tester VAS 5097 A
cardiagn.com
NOTE:  If battery tester VAS 5097A is used, it is not necessary to remove battery.
The battery does not need to be disconnected either.
Perform battery load test

 Read battery tester operating instructions.
 Connect test lead clamps to battery terminals as shown in battery tester operating instructions.
The clamps must make good contact with battery poles.
 Load current depends on battery capacity and must be adjusted on the tester --> battery tester operating
instructions.
 Perform battery load test according to operating instructions.
Tester display during battery load test
Note following tester evaluations:
Tester Evaluations
Display on battery tester Delivery inspection Inspection service
Starting output very good Battery OK Battery OK
Starting output good Battery OK Battery OK
Starting output sufficient Replace battery Recharge battery 1)
Starting output poor Replace battery Recharge battery 1)
Starting output very poor Replace battery Replace battery 2)
Not testable Replace battery Replace battery 2)
12:49:47 AM Page 10
 Replace battery. --> - 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL
Regarding battery load test:
Because of the high load on the battery during this test (a high current flows) the battery voltage lowers.
If the battery is OK, the voltage only goes down to the minimum voltage specification.
If the battery is malfunctioning or only faintly charged, the battery voltage will drop rapidly to below the
displayed minimum voltage.
After the test, this low voltage remains steady over a longer time before the voltage slowly increases.
Brake system: Visual inspection for leaks and damage
 Check the following components for leaks and damage:
cardiagn.com
 Brake master cylinder
 Brake booster
 ABS Hydraulic unit
 Brake calipers
 Check that brake hoses are not twisted.

 Ensure brake hoses do not come in contact with any vehicle components when steering is at full lock.
 Check brake hoses for porosity, bubbles and cracks.
 Check brake hoses and pipes for chafing.
 Check all brake line connections for secure mounting, leaks, or corrosion.
Brake pads: Checking thickness
WARNING: At a pad thickness of 7 mm (including backing plate) the brake pads have
reached their wear limit and must be replaced (repair measure). Inform the
customer.
Front disc brake pads:
12:49:47 AM Page 11
Fig. 8: Determining Thickness Of Inner Pad By Visual Check

cardiagn.com
Rear disc brake pads:

Tires: Checking condition, wear pattern and tread depth and adjusting tire pressure.
Tires, checking
NOTE:  For reasons of safety only tires of same type and tread pattern should be
fitted on a vehicle!
 On All Wheel Drive vehicle tires of the same type and tread pattern must
be used. Otherwise the center differential may be damaged.
12:49:47 AM Page 12
Delivery inspection
Inspection service
 Check running surfaces and side walls for damage, remove foreign material, if necessary.
 Check tires for scuffing, one sided wear, porous side walls, cuts and fractures.
WARNING: Report any damage to customer and mark repair order accordingly.
Checking tire wear pattern
 The wear pattern of the front wheels can be used to assess whether a check of the track and camber is
necessary:
cardiagn.com
 Feathered edges of the treads may indicate faulty toe adjustment.
 One-sided tread wear is mainly attributed to incorrect camber.
NOTE:  When wear of this nature is noticed determine cause by performing

alignment checks (repair measure).
Check tread depth.
 Minimum depth: 1.6 mm
NOTE:  This value may vary for individual countries due to different legislative
regulations.
Fig. 10: Checking Tire Tread Depth

12:49:47 AM Page 13
 The minimum tread depth is reached when the tires have worn down level with the 1.6 mm high tread
wear indicators - arrows - positioned at intervals around the tire.
 If the tread depth is approaching the legal minimum permissible depth, the customer must be informed.
Tire pressure, adjusting
cardiagn.com
Fig. 11: Identifying Tire Pressure Values For Summer Tires On Sticker
Tire pressure values for summer tires are on the sticker on the inside of the fuel tank lid.
NOTE:  Observe that the inflation pressure specifications on the sticker refer to
the air pressure of cold tires. Do not reduce increased pressures on warm
tires.
 On vehicles with Tire Pressure Monitoring System, changed tire pressures
must be stored. --> Tire Pressure Monitoring System: Programming tire
pressures
 When using winter tires, the tire pressure must be increased about 0.2 bar.
Spare wheel
 Spare wheel with standard tire
Keep the highest pressure intended for the vehicle
 Mini spare tire
Pressure is on side of tire
 Tire repair kit
Check --> Tire repair kit: Checking
NOTE:
12:49:47 AM Page 14
 Tire valves must be sealed with valve caps. Otherwise, dirt can enter valve
needle which becomes jammed and can no seal shut.
Brake fluid level, dependent on lining wear: Check
WARNING:  Brake fluid is poisonous. Due to its caustic nature, it must also
 Brake fluid is hygroscopic, meaning that it absorbs moisture from
the surrounding air, and must therefore always be stored in air-tight
containers.
 Please observe the following:
cardiagn.com
Delivery inspection

 Fluid level must be at MAX mark
NOTE:  To prevent the brake fluid from overflowing from the reservoir, the level
must not be over the MAX mark.
Inspection service
When driving, fluid level drops slightly from use and automatic brake pad adjustment.
 Always check fluid level in conjunction with brake pad wear:
12:49:47 AM Page 15

 When brake pads are new or if there is still enough brake lining left, the brake fluid level must be
between MIN and MAX marks.
cardiagn.com
 With brake fluid at MIN mark or slightly above, topping off brake fluid is not necessary when wear limit
of brake pads has been almost reached.
WARNING: If brake fluid level is below MIN mark, check brake system (repair
procedure), before adding brake fluid.
Brake fluid: Changing
Fig. 14: Identifying Brake Filler And Bleeder Unit VAS 5234
 VAS 5234 Brake filling and bleeding tool
12:49:47 AM Page 16
Fig. 15: Identifying Brake Filler And Bleeder Unit V.A.G 1869
 V.A.G 1869 Brake filling and bleeding tool with Adapter set V.A.G 1869/4
cardiagn.com
WARNING:  Brake fluid must never come into contact with fluids containing
mineral oils (oil, gas, cleaning solutions). Oils containing minerals
damage seals and sleeves on brake systems.
 Brake fluid is poisonous. Due to its caustic nature, it must also
 Brake fluid is hygroscopic, which means that it absorbs moisture
from the air. Always store brake fluid in air-tight containers.
 Wash off brake fluid spillage using plenty of water.
Observe operating instructions for VAS 5234 or for V.A.G 1869 !
Fig. 16: Identifying Brake Fluid Reservoir Cap

12:49:47 AM Page 17
 Remove brake fluid reservoir cap - 1 -.
WARNING:  The strainer in the brake fluid reservoir must not be removed.
 Remove brake fluid reservoir plug - arrow -.
cardiagn.com
 Connect suction hose from VAS 5234 or V.A.G 1869 to tube - 1 - of brake fluid reservoir.
 Extract as much brake fluid as possible using suction hose from VAS 5234 or from V.A.G 1869 or with
extractor bottle.
 Install brake fluid reservoir plug.
WARNING: Do not reuse, (used) extracted brake fluid.
12:49:47 AM Page 18
 Install adapter - 1 - to brake fluid reservoir.
cardiagn.com
 Connect filler hose - 2 - from VAS 5234 or V.A.G 1869 to adapter.
Vehicles with manual transmission:
 Pull cover cap off clutch slave cylinder bleed screw.
 Place extractor bleeder hose - 1 - on clutch slave cylinder bleeder screw, open bleeder screw, and let
about 100 ml drain out. Close bleeder screw and install cover cap.
 Operate clutch pedal several times.
12:49:47 AM Page 19
Continued for all vehicles:
 Remove caps from the bleeder screws.

 Connect extractor bleeder hose - 1 - to front left bleeder screw, open bleeder screw and allow about 200
ml to flow out. Close bleeder screw.
Repeat work sequence on other side of vehicle at front.
 Connect extractor bleeder hose - 1 - to rear left bleeder screw, open bleeder screw and allow about 200 ml
to flow out. Close bleeder screw.
Repeat work sequence on other side of vehicle at rear.
Table - Sequence / quantity of brake fluid
front left 200 ml
cardiagn.com
front right 200 ml
Left rear 200 ml
Right rear 200 ml
Total amount * See footnote 1,000 ml
* Including brake fluid extracted from brake fluid reservoir and quantity from clutch slave cylinder.
 Fit cover caps to brake caliper bleed screws.

 Move filler lever on VAS 5234 or V.A.G 1869 to position - B - (see operating instructions).
 Take filler hose off adapter.
 Unscrew adapter from brake fluid reservoir.

 Check brake fluid level and correct if necessary.

 Install cap to brake fluid reservoir.
12:49:47 AM Page 20
 Check pedal pressure and brake pedal free play. Free play: Max. 1 / 3 of pedal travel
Set digital clock
Vehicle is equipped with a radio or quartz clock.
Radio clock
If an acceptable radio clock signal is received, clock automatically switches to "radio-controlled quartz clock"
operating mode. The radio clock reception symbol (radio tower radiating waves) appears in display. If the clock
does not receive a valid signal, it automatically switches to "quartz clock" mode after 3 days and radio clock
reception symbol goes out.
Quartz clock
Set hour
cardiagn.com
 Press "MODE" button; hour display blinks.
 Press "+" button to advance hour display.
 Press "-" button to reverse hour display.
Set minute
 Press "MODE" button until minute display blinks.

 Press "+" button to advance minute display.
 Press "-" button to reverse minute display.
Set date
 Press "MODE" button until date display blinks.

 Press "+" or "-" button to set day.
 Press "MODE" button again, month display blinks.
 Press "+" or "-" button to set month.
 Press "MODE" button again, year display blinks.

 Press "+" or "-" button to set year.
Electric windows: Check positioning
Electric windows forget current position and automatic lowering and raising function when battery is
disconnected.
Activate automatic lowering/raising function as follows:
12:49:47 AM Page 21
 Raise windows with electric window regulators up to stop.

 Then operate all window switches again for at least 1 second in "close" position to activate automatic
lowering/raising.
 Press switch down. Window must lower to stop by itself.
DTC memory: Retrieving with VAS 5051/ 5052
cardiagn.com
Fig. 21: Connecting Data Link Connector (DLC)

 Vehicle - Self-diagnosis
 Gateway - Installation list
 Read control module with stored DTC memory.

 Correct relevant malfunctions with customers approval.
Check vehicle key function
 Separate keys so that each can be checked individually for function.

 Mechanically lock and unlock drivers door with each key.
 Remove radio operation (press a remote control operation button)
 Insert each key in ignition and switch ignition on. Immobilizer key symbol in instrument cluster must go
12:49:47 AM Page 22
out after two seconds. If key symbol blinks, key is not programmed to immobilizer. Guided Fault
Finding; Program vehicle key
 Remove radio operation (press a remote control operation button)
NOTE:  Enter number of keys checked and delivered to customer in delivery

protocol.
Front axle joints: Seal boots, checking play and secure fit.
NOTE:  Perform this test with vehicle on lift (wheels hanging freely).
Tie rod ends
 Check play by moving tie rods and wheels.
cardiagn.com
 Check all around ball joint boots - arrow - for damage and correct seating. Use a mirror, if necessary.
Fig. 22: Identifying Lock Nut

 Make sure lock nut - 1 - is tightened to 40 Nm.
All control arms
12:49:47 AM Page 23
cardiagn.com
Fig. 23: Identifying Ball Joint Boots
 Check all around ball joint boots - arrows - for damage and correct seating. Use a mirror, if necessary.

Control arm
Fig. 24: Identifying Bearing Housing And Control Arm

 With unloaded wheels, check relative movement of wheel bearing housing to control arm.
 By raising and lowers the wheels several times by hand - arrow - the relative movement between wheel
bearing housing and control arm can be observed.
 If relative movement when lifting or lowering gives evidence of play that can be felt or seen, control arm
12:49:47 AM Page 24
must be replaced.
Drive shaft boot
 Check all around interior and exterior drive shaft boot for damage and correct seating. Turn wheel, if
necessary.
 By turning the front wheels, tears can be found in their early stages.
 Drive shaft boot damage can usually be recognized by leaking lubrication.
Noise insulation: Removing
Vehicles with auxiliary heater:
cardiagn.com
Fig. 25: Identifying Exhaust Pipe Fasteners
 Remove parking/auxiliary heater exhaust pipe screws - arrows - on noise insulation.
All:
Fig. 26: Removing Sound Insulation

12:49:47 AM Page 25
 Remove quick-release screws - arrows -.
Power steering: Check for leaks and fluid level, top off power steering fluid, if necessary
 With engine not running, move front wheels in straight-ahead position.
Cold fluid (exterior temperature approx +20 ° C)
 Remove cover.
 Clean dipstick with clean cloth.
 Screw cap on hand-tight and remove again.
Screw cap fully in to get an accurate fluid level reading.
cardiagn.com
Fig. 27: Checking Fluid Level
 Check fluid level: Fluid level must be in area of "MAX" marking.
Warm fluid (engine fluid temperature +80 ° C)
 Check fluid level: Fluid level must be 10 mm above "MAX" marking.
NOTE:  If fluid level is above specified range, fluid must be extracted off.
 If the fluid level is below the specified level, check the hydraulic system for
leaks. It is not enough to simply top off with fluid.
 Do not use power steering fluid that has drained out.
Rear lid hinges: Lubricate
 Open rear lid

 Remove left/right lid hinge cover if present.
12:49:47 AM Page 26
Fig. 28: Lubricating Hinge Joints

 Lubricate each of the four hinge joints on both rear lid hinges - arrows -.
cardiagn.com
NOTE:  Included spray tube must be inserted in sprayer head to aim spray.
 Shake spray can about five times.
 Spray must not be shaken too long or hard because otherwise spray oil
will foam up and its lubricating ability is reduced.
 Clean excess fluid from body and joints.
Calibrate rearview mirror with compass
--> - 68 - INTERIOR EQUIPMENT
Instrument cluster: Adapt language version
12:49:48 AM Page 27
cardiagn.com

 Service work
 Language adaptation

 K-lead adapter VAS 6017B must be used.
A/C system: Check function, set temperature to 72 F (22 C)
 Check all climate control functions: Owners manual
12:49:48 AM Page 28
Fig. 30: Checking Whether 72F (22C ) Is Set In Both Display Fields
 Check whether 72 ° F (22 ° C ) is set in both display fields.
cardiagn.com
 Set temperature as follows, if necessary:
 Press the "AUTO" button.
 Set temperature on drivers and passengers side to 72 ° F (22 ° C) with "+" and "-" buttons.
Cooling system: Check freeze protection, add coolant, if necessary
NOTE:  All new engines are filled with coolant additive G 12 Plus according to TL
VW 774 F (purple color). G 12 Plus can be mixed with the previous coolant
additives G 11 and G 12 (red). Ensure that the system is replenished only
with G12 Plus (due to its positive properties).
 G 12 Plus is suitable as a filled-for-life filling for cast iron and all-aluminum
engines and gives optimum protection against freezing, corrosion
damage, scaling and over-heating.
 G 12 Plus increases the boiling point to 275 ° F (135 ° C) and ensures for a
better heat dissipation.
 The coolant portion of the mixture must amount to at least 40% (freeze
protection to -13 ° F [-25 ° C]) and should not exceed 60% (freeze
protection to -40 ° F [-40 ° C]). Otherwise the freeze protection will be
reduced and the cooling efficiency will be worsened.
 The freeze protection must be ensured to approximately -13 ° F (-25 ° C).
Checking freeze protection and adding coolant additive if necessary
12:49:48 AM Page 29
cardiagn.com
Fig. 31: Identifying Refractometer T10007
 Refractometer T10007
NOTE:  Read the bright/dark boundary to obtain an accurate reading for the
following tests. Place a drop of water on the glass to improve the
readability of the bright/dark boundary. The bright/dark boundary can be
clearly recognized on the "WATERLINE".
 Check the concentration of the coolant additive using refractometer
T10007 (operating instructions).
Fig. 32: Identifying Refractometer Scales

The scale - 1 - of the refractometer is designed for coolant additives G 12; G12 Plus and G11.
Scale - 2 - refers only to coolant additive G 13. (previously L80)
12:49:48 AM Page 30
NOTE:  The freeze protection must be ensured to approximately -13 ° F [-25 ° C].
 If for climatic reasons greater freeze protection is required, the amount of
G 12 Plus can be increased, but only up to 60% (freeze protection to about
-40 ° F [-40 ° C]), otherwise freeze protection and cooling effectiveness will
be reduced.
 If freeze protection is insufficient, drain off required quantity shown in
freeze protection table and add coolant additive G 12 Plus.
Freeze protection to ° C Difference amount in liters

Actual value Specified value 4-cylinder engines 6-cylinder engines 8-cylinder engines
0 -25 3,5 5,0 5,0
-35 4,0 6,0 6,0
cardiagn.com
-5 -25 3.0 4,5 4,5
-35 3,5 5,5 5,5
-10 -25 2.0 3,5 3,5
-35 3.0 4,5 4,5
-15 -25 1,5 2.5 2.5
-35 2.0 3,5 3,5
-20 -25 1,0 1,5 1,5
-35 1,5 2.5 2.5
-25 -35 1,0 1,5 1,5
-30 -35 0,5 1,0 1,0
-35 -40 0,5 0,5 0,5
 Check coolant additive concentration after test drive again.
Checking coolant level and adding coolant if necessary
 Check coolant level in expansion tank with engine cold.
12:49:48 AM Page 31
Fig. 33: Checking Coolant Level

 Delivery inspection: Coolant level above the "MIN marking" - arrow -.
cardiagn.com
 Inspection service: Coolant level above the "MIN marking" - arrow -.
 If coolant is too low, add required amount according to mixture ratio.
NOTE:  Determine cause of fluid loss which cannot be attributed to normal use
and rectify (repair measure).
Mixture ratio:
Freeze protection to Coolant additive G 12 Plus / TL Water

VW 774 F
-25 ° C approx. 40% approx. 60 %
-35 ° C approx. 50 % approx. 50 %
-40 ° F approx. 60 % approx. 40%
NOTE:  Coolant additive G 12 Plus conforming to TL VW 774 F prevents freeze and

corrosion damage, scaling, and raises the boiling point. For these
reasons, the cooling system must be filled with radiator freeze and
corrosion protection fluid all year round.
 Especially in countries with tropical climates or when vehicle is driven
under heavy load, the coolant improves the engine reliability by its
increased boiling point.
 The coolant concentration must not be reduced by adding water, even
during the warmer season. The coolant additive ratio must be at least 40%.
Ribbed belt: Replacing
12:49:48 AM Page 32
 Ribbed belt, removing and installing: --> - 13 - ENGINE - CRANKSHAFT, CYLINDER BLOCK
Air cleaner: Clean air filter housing and replace filter
cardiagn.com
Fig. 34: Identifying Intake Hose And EVAP Valve Retainer
NOTE:  In various engine versions, a snow screen is located in intake hose - A -.

Snow screen must be removed and cleaned.
4-cyl. 1.8L 5V Turbo engines --> 4-cyl. 1.8L 5V Turbo engines:
4-cyl. 2.0L Turbo FSI engines --> 4-cyl. 2.0L TFSI engines
6-cyl. 3.0L engines --> 6-cyl. 3.0L engines
6-cyl. 3.2L engines --> 6-cyl. 3.2L engines
8-cyl. 4.2L engines (RS4) --> 8-cyl. 4.2L engines (RS4)
4-cyl. 2.0L TFSI engines
12:49:48 AM Page 33
cardiagn.com
Fig. 36: Identifying Upper Part Of Air Filter Bolts

 Disconnect electrical connector from Mass Air Flow (MAF) Sensor G70.
 Open clamp from air guide hose to turbocharger and remove this at Mass Air Flow (MAF) Sensor G70.

4-cyl. 1.8L 5V Turbo engines:
12:49:48 AM Page 34
cardiagn.com
Fig. 38: Identifying Hose Clamp And Evaporative Emission (EVAP) Canister Valve
 Open hose clamp - 1 - and remove line from Evaporative Emission (EVAP) canister valve.
 Remove line - 3 - and remove both screws - 2 -.
 Remove upper part of air filter from bracket and pivot toward engine side.

6-cyl. 3.0L engines
12:49:48 AM Page 35
cardiagn.com
Fig. 40: Identifying Air Duct, Air Intake Hose, Electrical Connector And Mass Air Flow (MAF) Sensor
G70

G70.
 Remove both fuel lines from bracket on upper part of air filter housing.
12:49:48 AM Page 36
6-cyl. 3.2L engines
cardiagn.com
Fig. 42: Identifying Air Duct, Clean Air Tube Clamp, Fuel Line, And Pipe Connection

 Open clean air tube clamp - 4 - and remove from air filter housing.
 Unclip fuel line - 3 -.
12:49:48 AM Page 37
cardiagn.com
G70.
 Remove line -1- and remove both screws - 2 -.
 Remove both fuel lines from bracket on upper part of air filter and remove this upward.

12:49:48 AM Page 38
8-cyl. 4.2L engines (RS4)
cardiagn.com
 Disengage fuel line - 1 - at upper part of air filter housing.
Fig. 46: Identifying Air Duct And Mass Air Flow Sensor G70 Electrical Connector

 Loosen hose clamp - 2 - and remove air intake hose from upper part of air filter.
 Disconnect electrical connector - 1 - from Mass Air Flow Sensor G70.
 Remove hoses - 6 - , - 4 - and - 3 - from bracket.
 Now remove screws - 5 - and remove upper part of air filter housing upward.
 Follow notes * See note
12:49:48 AM Page 39
NOTE:  If the air filter insert is heavily soiled or soaked, dirt particles or moisture
can reach the Mass Air Flow Sensor G70 and cause an incorrect air flow
reading. This causes lack of performance because a lower injection
amount is calculated.
 Always use an original air filter insert.
 Hose supports and charge air system hoses must be free of oil and grease
before installation. Do not use any lubricant containing silicone when
installing.
 Air filter housing must be clean.
 Secure all hose connections with hose clamps that match current
standard production.
 When cleaning air filter housing with compressed air, observe the
following: To avoid malfunctions, cover critical air carrying engine
components such as Mass Air Flow (MAF) sensor, air inlet tube, etc. with a
cardiagn.com
clean cloth.
 Check drain hose in bottom side of air filter or dirt and adhesion (clean, if
necessary).
 Check mass air flow sensor and air guide hose (clean air side) for salt
residue, dirt and leaves.
 Check air duct from lock carrier to air filter housing for dirt and leaves.
 When installing air filter insert, ensure it is centered in mount on bottom of
air filter.
 Carefully and gently place upper part of air filter on lower part. Ensure
upper part of air filter is not sitting crooked on air filter insert (note air filter
insert sealing lip).
 Ensure secure fit from air guide hose to Mass Air Flow (MAF) Sensor G70.
Hood catch: lubricating
Fig. 47: Identifying Lubrication Points On Hood Safety Catch

12:49:48 AM Page 40
 Lubricate hood safety catch only on lubrication places indicated - arrows -.
Engine cover: Removing
cardiagn.com
Fig. 48: Removing Engine Cover
4-cyl. Gasoline engines
 Remove bolts or nuts - arrows - and remove engine cover(s).
Fig. 49: Removing Cover In Engine Compartment (Right Side)

Remove cover - 1 - at right in engine compartment.
12:49:48 AM Page 41

cardiagn.com
V8 4.2 gasoline engines
Engine (from above and below) and engine compartment: Visual inspection for leaks and damage
Perform visual check as follows:
 Remove engine cover --> Engine cover: Removing.

 Check engine and engine compartment for leaks and damage.
 Check lines, hoses and connections on following systems for leaks, chafing, porosity and cracks:
 Fuel system
 Cooling and heating system
 Brake system
12:49:48 AM Page 42
 Perform visual inspection from below using same viewpoints as when vehicle was on lift and noise
insulation removed.
Continuously Variable Transmission (CVT) 01J: Changing ATF
 Continuously Variable Transmission (CVT) 01J: Change ATF --> - 37 - AUTOMATIC

TRANSMISSION - CONTROLS, HOUSING
Engine oil: Drain/extract, replace oil filter
WARNING: Oil extraction not permitted with various engine types! See maintenance
table.
cardiagn.com
NOTE:  Perform oil change at operating temperature.
 Hazet tension band 2171-1

 or
 Oil filter wrench 3417
 Oil extractor V.A.G 1782
Fig. 52: Identifying Oil Drain Adapter T 40057 (2.0 TFSI)

 Oil Drain Adapter T 40057 (2.0 TFSI)
12:49:48 AM Page 43
4-cyl. gasoline engines --> 4-cyl. gasoline engines
4-cyl. TFSI engines --> 4-cyl. TFSI engines
6-cyl. 3.2L FSI gasoline engines --> 6-cyl. 3.2L FSI gasoline engines
8-cyl. 4.2L MPI gasoline engines --> 8-cyl. 4.2L MPI gasoline engines
8-cyl. 4.2L FSI gasoline engines, RS4 --> 8-cyl. 4.2L FSI gasoline engines, RS4
cardiagn.com
Fig. 53: Identifying Oil Filter
 Loosen oil filter - arrow - using oil filter wrench 3417 or tension band Hazet 2171-1.
 Remove oil filter.

 Observe installation note on oil filter.
 Open oil drain plug or extract engine oil.
 Clean oil filter sealing surface on engine.
12:49:48 AM Page 44
Fig. 54: Identifying Oil Filter Unit And Hoses

 Install new filter and tighten.
cardiagn.com
WARNING: After changing oil filter unit, check clearance of hoses - arrows - going
from oil cooler to adjacent components. Correct the position of the oil
cooler, if necessary.

 Fill up with engine oil, specifications --> Engine oil: Fill.
Oil drain plug 4-cyl. gasoline engines 30

4-cyl. TFSI engines
 Remove noise insulation --> Noise insulation: Removing.
NOTE:  Before removing oil filter, motor oil must be drained from filter so that it
does not drain onto engine and attached parts.
12:49:48 AM Page 45
cardiagn.com
Fig. 55: Identifying Valve Protection Cap And Oil Filter Housing Bottom
 Remove bottom valve protective cap - 1 -.

 Remove ball head hose from Oil Drain Adapter T 40057 and turn threaded bolt in bottom oil filter
housing bottom valve - 2 - under a slight resistance is felt.
 Now place ball head hose on threaded bolts and turn Oil Drain Adapter T 40057 to stop - a clear snap of
the drain valve will be heard.
 Allow oil filter to run empty.
WARNING: Hot engine oil
Fig. 56: Identifying Remove Oil Drain Adapter T 40057
12:49:48 AM Page 46
 Remove Oil Drain Adapter T 40057.

 Check whether bottom valve - 1 - is flush and not crooked, as in illustration (A02-0423).
 Remove protective cap.
 Open oil filter housing - 2 - with Oil Filter Wrench 3417 or with socket AF 36, e.g. Socket AF 36 T10125
and remove oil filter.
cardiagn.com
Fig. 57: Identifying Filter Insert And Gasket
 Replace filter insert - 4 - and gasket - 3 -.

 Note position of service flag on sealing ring (see arrow)

 Clean sealing surface on oil filter housing.
 Smooth side of sealing ring must face toward outside
 Screw on filter housing and tighten.
 Install oil drain plug with new gasket.
 Fill up with engine oil, specifications --> Engine oil: Fill.
Oil filter 25+5
Oil drain plug 30
12:49:48 AM Page 47

6-cyl. 3.2L FSI gasoline engines
NOTE:  Loosen the cap before draining / extracting, so that the engine oil can run
cardiagn.com
out of the oil filter housing.
Fig. 58: Identifying Coolant Reservoir And Oil Filter Cover

 Remove coolant reservoir - 1 - and lay aside.

 Remove oil filter cover with socket wrench SW 36 - 2 -.
 Clean sealing surfaces oil filter cover and at oil filter housing.
 Replace oil filter insert..
12:49:49 AM Page 48
Fig. 59: Identifying Sealing Ring On Cap

Sealing ring on cap, replacing
cardiagn.com
 Remove sealing ring at pull tab - arrow A - from cap - 1 -.
 Insert new sealing ring - 2 - with semicircular profile in groove - arrow B - on cap.
 The pull tab - arrow A - must face upward.

 Smooth side of sealing ring - 2 - must face toward outside
Fig. 60: Identifying Oil Filter Housing O-Ring

O-ring, inserting in oil filter housing
 Insert O-ring - 2 - in groove - arrow - on oil filter housing - 1 -.

 Engage new oil filter insert in oil filter cover.
 Install oil filter cover.
12:49:49 AM Page 49
 Install coolant reservoir.

 Remove noise insulation.
 Open oil drain plug on oil pan or extract engine oil.
 Install oil drain plug.
NOTE:  Oil drain plug is installed without seal.

Oil filter cover 25
Oil drain plug on oil pan 30
 Fill motor oil. --> Engine oil: Fill
cardiagn.com
8-cyl. 4.2L MPI gasoline engines


12:49:49 AM Page 50
cardiagn.com


Oil filter cover 25
Oil drain plug 50
12:49:49 AM Page 51
8-cyl. 4.2L FSI gasoline engines, RS4
cardiagn.com
Fig. 64: Identifying Screws And Line
 Loosen screws - 1 - and unclip line - 2 -.

 Lay aside bracket.


12:49:49 AM Page 52
cardiagn.com


 Open oil drain plug and drain engine oil.
Oil filter cover 25
Oil drain plug 25
12:49:49 AM Page 53

 Do not extract engine oil!
Engine oil: Fill
NOTE:  Please follow specified engine oil capacity and oil standards in the ELSA
maintenance table.
Engines with turbocharger:
 After the engine oil and oil filter have been replaced, observe the following when first starting the engine:
 As long as the oil pressure warning light in the instrument panel insert flashes, the engine is only to run at
idle. Do not touch the accelerator pedal! Bumping the accelerator pedal can damage the turbocharger or
destroy it completely
cardiagn.com
 The full oil pressure achieved and the engine can be accelerated only when the warning light extinguishes
All:
 Check engine oil level --> Engine: Oil level, checking.
Engine: Oil level, checking
NOTE:  Oil temperature at least 140 ° F (60 ° C).

 Vehicle must be in level position.
 After stopping engine, wait a few minutes to allow oil to flow back into oil
pan.
 Pull out oil dipstick and wipe with clean rag. Replace dipstick and push
down to stop.
 Pull out dipstick again and read oil level.
Fig. 68: Identifying Markings On Dipstick
12:49:49 AM Page 54
Markings on dipstick:
NOTE:  Oil level must not exceed - a - mark on dipstick.
Navigation: Eject button, unlocking
cardiagn.com

 Guided functions
 Service work
 J401 - Navigation, Eject button, locking/unlocking

Test drive: Perform
To what extent the following can be checked is dependent upon the vehicle equipment and local conditions
(urban/country).
 The following should be checked by means of a road test:
12:49:49 AM Page 55
 Engine: Output, misfiring, idling speed, acceleration

 Clutch: Pulling away, pedal pressure, odors
 Gear selection: Ease of operation, shift lever position
 Automatic transmission: Selector lever position, shift lock / ignition key removal lock, shift behavior,
instrument panel insert display
 Foot and parking brake: Function, free travel and effectiveness, pulling to one side, juddering, squeal
 ABS function: A pulsing at the brake pedal must be felt when performing ABS controlled braking
 Steering: Function, steering free play, steering wheel centralized when wheels are in straight ahead
position
 Tilt/slide sunroof: Function
 Cruise Control System (CCS): Function

 Radio: reception, SCV, interference
cardiagn.com
 Driver Information System (DIS): Functions
 A/C system: Function
 Vehicle: Moving off line when traveling straight ahead (level road)
 Imbalance: Wheels, drive shafts
 Wheel bearings: Noises
 Engine: Hot starting behavior
Wheel bolts: Tighten to correct torque setting
Center cap
Fig. 70: Identifying Removal Hook

The removal hook - A - for removing the center cap is located in the vehicles tool kit.
Wheel bolts
12:49:49 AM Page 56
The adapter to loosen/tighten the anti-theft wheel bolts is located with the vehicle tool kit.
Place adapter with vehicle tool kit after completing work.
NOTE:  Be sure to tighten wheel bolts in diagonal sequence to the following

specified torque:
Wheel bolts 120
Correct wheel installation
 When installing wheels, you must observe the following points to ensure wheels fit securely:
 Always tighten wheel bolts to the specified torque so the wheel bolt seats in rim are not deformed.
cardiagn.com
 When installing a wheel, do not tighten first wheel bolt immediately (for example, with an impact
wrench). This would prevent other bolts from centering rim properly when they are screwed in. Rim
could then become loose, even if tightened to specified torque.
 Before installing wheels, check for rust/corrosion in wheel bolt seats and contact surfaces between rims
and hubs, removing if necessary. Otherwise, the wheel bolts can lose tension after installation and the rim
can come loose.
WARNING:  If the above points are not observed, wheels can come loose and the
wheel bolt seats in rim can be deformed.
 The deformity could be so small that you can't see it.
 But even small deformities in the wheel bolt seats can prevent the
wheel from fitting securely, so that it becomes looser and looser.
Radio: Activate anti-theft coding by entering security code
Radio units are shipped with a fixed code. Fixed code means that every radio unit with anti-theft coding has
been programmed with its own code. This code is not active from the factory. To increase anti-theft protection,
there is no longer a radio card in the radio and navigation system owners manual. The entry of the radio code is
no longer described in the owners manual.
The Anti-theft coding on a unit that is ready to play is activated by entering the fixed code.
On chorus II+, concert II+ and symphony II+ radio systems, enter the radio code as follows
 Switch on radio. "Code 1000" appears in the display.

 Press upper left control button "X___" -arrow- until first digit of radio code appears in display.
 Enter remaining three radio code digits with other three control buttons
 Press "ENTER" control button. The radio is coded.
12:49:49 AM Page 57
Fig. 71: Identifying Radio Controls

cardiagn.com
If the radio code is entered incorrectly two times and "Code Safe 2" appeared in the display, use the following
procedure
Leave radio switched on approx. 60 minutes. After 60 min., "Code Safe / Code 1000" appears in the display and
the radio is switched off
Enter radio code again.
On navigation system BNS 5.0, enter radio code as follows
 Switch on navigation system

 Enter PIN using Speller
 Confirm entry with "OK"
NOTE:  Please inform the customer that he can only learn the anti-theft radio code
from the service advisor
 That way, thieves really cannot use the radio!
Tire Pressure Monitoring System: Programming tire pressures
Specified values should also be saved with every tire pressure adaptation, e.g. when vehicle load condition
changes, so that Tire Pressure Monitoring System can be as useful as possible. Do this as follows:
 Press Reset button on windshield washer lever.

 Select Tire Pressure Monitoring System.
 Select Save tire pressures.
12:49:49 AM Page 58
NOTE:  Saving of tire pressures must be started after each deliberate change to
specified values.
Tire repair kit: Checking
cardiagn.com
Fig. 72: Identifying Durability Date In Tire Repair Kit
On vehicles with a tire repair kit, check durability date - arrow -.
NOTE:  If expiration date has passed, replace bottle.
Windshield washer system: Checking nozzle setting, adjusting nozzles if necessary
Fig. 73: Identifying Adjustment Tool T10127 Equipped With Needle 3125/ 5 A
 Windshield washer aiming tool T10127 equipped with replacement tip 3125/5A.
12:49:49 AM Page 59
NOTE:  Never use a needle or a similar object, since it may damage the water
hoses in the spray nozzle!
Windshield spray jet setting
cardiagn.com
 Dimension - a - = 250 to 275 mm

 Dimension - b - = 465 to 490 mm
 Dimension - c - = 270 to 415 mm
 Dimension - d - = 140 to 225 mm
NOTE:  Adjusting dimensions are calculated from outer edge of windshield.

T10127 with replacement tip 3125/5A.
Rear window spray jet setting
12:49:49 AM Page 60
Fig. 75: Identifying Windshield Wiper Dimensions

 Adjust spray jets with Washer Jet Adjuster T10127 so fluid sprays over the wiper onto the rear window at
the places shown.
cardiagn.com
 Dimension - a - = approx. 125 mm
 Dimension - b - = approx. 295 mm
 Dimension - c - = approx. 5 mm
Headlamp washer system: Check spray jet setting.
Headlamp cleaner spray jets are set at the factory and do not need to be adjusted.
Windshield wiper blades: Checking park position
Front windshield wiper blade park position
 Switch windshield wipers on and off and allow to run to end position.
Fig. 76: Checking Windshield Wiper Blade Tips Position

 Check whether wiper blades rest again front window in indicated position.
12:49:49 AM Page 61
 Dimension - a - = 24 mm
 Dimension - b - = 44 mm
NOTE:  Dimensions indicate distance of wiper blades to plenum chamber cowl

panel grille on lower window edge.
 If necessary, unscrew wiper arm, align and tighten nuts.
 Activate mist wipe and check adjustment.
Wiper arm to wiper shaft 21
Wiper blade park position, rear window
 Let wiper motor run to end position.
cardiagn.com
 Switch ignition off and remove ignition key.
Fig. 77: Identifying Cover

 Carefully spread cover - arrows - and lift.
12:49:49 AM Page 62
Fig. 78: Identifying Spray Jets And Hex Head Nuts

 Carefully remove spray jets - 2 -.

 Loosen hex head nuts - 1 - a few turns.
 Loosen wiper arms by tilting wiper shaft slightly.
cardiagn.com
Fig. 79: Identifying Dimensions For Wiper Blade On Rear Window
 Place wiper blade on rear window and adjust as follows:
 Dimension - a - = 15 to 20 mm
NOTE:  Dimension gives distance of wiper blade point to lower edge of window.
 Tighten wiper arm nut to 12 Nm.
 Activate wiper.
 Adjust wiper arm again, if necessary, and tighten nut.
 Check spray jet adjustment --> Windshield washer system: Checking
nozzle setting, adjusting nozzles if necessary.
Service interval display: resetting or adapting
NOTE:  Service display serves to remind the driver of service needed. The display
appears in the center display.
 Service indicators appears 1 month or 2.000 km before reaching service
interval. It disappears after 100 km. Example display: After a total driving
distance of 28,700 km, "SERVICE IN 1300 KM" appears.
12:49:49 AM Page 63

 The distance remaining to the service interval can be viewed via the center display menu by press button -
1 - once.
cardiagn.com
 When a service interval arrives, the text information appears in the center display for 5 seconds after
switching ignition on. It is shown after automatic transmission message and a possible navigation system
destination. Display: "SERVICE!".
Service display, resetting

12:49:50 AM Page 64

 Service work
 Combination Processor, reset WIV

 WIV = Wartungsintervall - Verlangerung (Maintenance Interval Extension)
Oil quality, adapting
cardiagn.com

 Service work
 Combination Processor, changing oil quality
12:49:50 AM Page 65
NOTE:  It is necessary to change oil quality if changed between inspection.

 Inspection Service = Oil quality 1
 WIV = Wartungsintervall - Verlangerung (Maintenance Interval Extension)
Maximum values, adapting
cardiagn.com

 Service work
 Combination Processor, adjusting maximum WIV value
Fixed interval maximum values
Minimum mileage in Km 15000

Maximum mileage in Km 15000
Maximum time interval in days 365
12:49:50 AM Page 66
NOTE:  WIV = Wartungsintervall - Verlangerung (Maintenance Interval Extension)

Service display, resetting without VAS 5051/5052
NOTE:  If reset without VAS 5051 or VAS 5052 , service display is automatically set
to fixed interval (15,000 km).
Resetting can be carried out using tester VAS 5051 or VAS 5052 in "Adaptation" function --> Service interval
display: resetting or adapting.
Service display can also be reset using the following procedure:
cardiagn.com
 Press Taste button - 1 - and switch on ignition at the same time.
After releasing button, display shows: "SERVICE IN ????Km" or "SERVICE!".
 Hold down button Taste - 2 - until text is reset to "SERVICE IN ????Km" or "SERVICE!".
Windshield/headlamp wiper system: Filling with fluid
 Fill washer fluid fully.
NOTE:  Always add a neutral pH window cleaner to washer fluid (freeze protection
in winter).
Vehicle Electrical System Control Module - J519: coding
12:49:50 AM Page 67
 Connect VAS 5051 --> DTC memory: Retrieving with VAS 5051/ 5052.
 Go To
 Body

 Electrical system (Highline or Lowline depending on vehicle equipment)
cardiagn.com
 Electrical system function
 J519 Vehicle Electrical System Control Module, coding
 Press button
Follow tester steps and confirm entry until following text appears:
OK J519 Vehicle Electrical System Control Module, coding
 Go To
 End
Dust and pollen filter: Replacing
NOTE:  Filter insert is available in different versions (with and without activated
charcoal insert as integrated odor Parts catalog.
 The filter is located beneath the fresh air plenum cover on the right side.
 Remove plenum chamber cover --> Plenum chamber cover: Removing.
12:49:50 AM Page 68

 Unclip cover - B - and remove forward.
cardiagn.com
 Remove dust and pollen filter - C - from housing.
NOTE:  When inserting filter in filter frame, observe flow-through direction - arrow
D-
 When installing, ensure cover - B - is seated correctly. It must be clipped
in at both catches - A - , otherwise water will run on dust and pollen filter
and into A/C unit.
Sunroof: Check function, clean guide rails and spray on lubricant spray
 Check sunroof for leaks.

 Clean guide rails.
 Spray guide rails.
 Check sunroof function.
Manual transmission/final drive: Check oil level, add oil if necessary
--> -

012/01W FRONT WHEEL DRIVE
01A ALL WHEEL DRIVE
01E ALL WHEEL DRIVE
 34 - CONTROLS, HOUSING for 6 SPD. MANUAL TRANSMISSION 0A3 ALL WHEEL DRIVE,
12:49:50 AM Page 69
INTERNAL COMPONENT SERVICING

 34 CONTROLS, HOUSING for 6-SPEED MANUAL TRANSMISSION 01X, FRONT-WHEEL
DRIVE
 34 CONTROLS, HOUSING 6-SPEED MANUAL TRANSMISSION 02X, FOUR-WHEEL DRIVE
 34 CONTROLS, HOUSING for 6-SPEED MANUAL TRANSMISSION 0A3, ALL WHEEL DRIVE
Headlamps: Check setting, adjust if necessary
The following test- and adjustment instructions are applicable to all countries. National guidelines or
regulations of the country must be observed.
Check and adjustment conditions
 Tire pressure OK.

 Lenses must not be damaged or dirty.
cardiagn.com
 Reflectors and bulbs OK.
 Vehicle must be properly loaded.
Load: Vehicle must be loaded with one person on the drivers seat, weighing 75 kg, otherwise vehicle must be
empty (curb weight).
The curb weight is the weight of the vehicle ready for operation with completely filled fuel tank (at least 90%),
including the weight of all equipment items carried for operation (e.g. spare wheel, tool, vehicle jack, fire
extinguisher etc.).
If the fuel tank is not at least 90% full, adjust the weight as follows:
 Read fuel level from fuel gauge. Calculate additional weight needed using the following table. Place extra
weight in luggage compartment.
Tank filling
Fuel level according to fuel gauge Additional weight in kg
1/4 52
1/2 35
3/4 17
Full 0
Example:
If the fuel tank is half full, place a weight of 35 kg in the luggage compartment.
NOTE:  For additional weight use containers filled with water. A container filled
with 5 liters of water weighs approx. 5kg.
12:49:50 AM Page 70
Vehicle must be rolled for several meters or the front and rear suspension must be bounced several times so that
the springs settle.
 Vehicle and headlamp adjuster must be on a level surface operating instructions for headlamp adjuster.
 Vehicle and headlamp adjuster must be aligned.
Ensure headlight adjuster is about 30 cm in front of headlight.
 Inclination must be set.
Inclination measurements are stamped in "%" at top of headlamp. The headlamps must be adjusted according to
these measurements. Percentage information is based on a projection distance of 10 meters. For example:
inclination of 1.0 % converts to approx. 10 cm.
Vehicles with manual headlight range adjuster:
cardiagn.com
 The headlight range adjuster thumb wheel must be in basic setting - 0 -.
Vehicles with automatic headlight range adjusting
NOTE:  To check/adjust headlights, they must always be placed in the basic

setting with the VAS 5051.
 Performing basic setting with VAS 5051 :
 connect VAS 5051 with ignition switched off.

12:49:50 AM Page 71
 Use K-lead adapter VAS 6017B.

 Go To
 Body
 01 - On Board Diagnostic (OBD) capable systems
cardiagn.com
 55-Dynamic Headlamp Range Control
 J 431-Dynamic Headlamp Range Control, Functions
 J 431-Headlamp Range Control Module, basic setting
 Press button
Follow the steps of the tester and confirm the entry until the following text appears:
J 431-Headlamp Range Control Module, basic setting
 Press button
 Follow test sequence
Headlamps, checking adjustment (with new test screen without 15 ° setting line)
 Switch ignition and low beams on
Fig. 87: Identifying Headlight Setting Line, Break-Away Point & Center Point
12:49:50 AM Page 72
 Horizontal light-dark border must contact hyphenated line - 1 - on test surface.

 Break-away point - 2 - between left horizontal part and rising part on right of light-dark border must run
vertically through central point - 3 -. The bright core of the light beam must be on the right of the vertical
line.
NOTE:  To make it easier to find break-away point - 2 - cover and uncover left half
of headlamp (as viewed when looking forward) a few times. Next, check
low beam again.
 After correct adjustment of dipped beams the center point of the main
beam must lie on the center mark - 3 -.
 For the previous test screen with 15 ° -setting line, adjust as for new test
screen. To avoid incorrect settings, ignore 15 ° setting line.
 If headlight adjustment is not OK: Adjust headlights:
cardiagn.com
Headlamps, adjusting
Fig. 88: Identifying Adjustment Screws For Main Headlight (Right)

Main headlight (right)
Adjusting screw on right headlight:
Placement on left headlight is similar.
 To adjust height, turn adjustment screws - 1 - and - 2 - with same number of revolutions.
 To adjust laterally, turn only adjustment screw - 2 -.
Fog lights:
Inclination figures:
 Fog lights 20 cm
12:49:50 AM Page 73
Fig. 89: Checking Whether Upper Light-Dark Border Touches Adjusting Line And Runs Across Entire
Test Screen Width Horizontally
Check whether upper light-dark border touches adjusting line and runs across entire test screen width
cardiagn.com

horizontally.
Fig. 90: Identifying Air Duct Grille, Bumper, And Adjustment Screw
 Remove air duct grille on inner side of bumper - arrow -.

 To change lamp range, turn adjustment screw - arrow -. Lateral adjustment is not possible.
NOTE:  Right fog light is shown in illustration. Adjusting screw on left fog light is
arranged symmetrically.
Other additional headlamps:
Accessory auxiliary headlamp systems must be checked and adjusted according to the guidelines valid for them.
Deactivate transport mode
Transport mode can be activated in instrument panel insert and in radio.
12:49:50 AM Page 74
Transport mode activated in instrument cluster has the following effects in comfort system central
module.
 SAFE LED in doors is no longer controlled

 Interior light, footwell lights and luggage compartment lights can no longer be switched on at terminal 15.
 At terminal 15, interior light is switched on for a maximum of 30 seconds when a door is opened.
 Anti-theft system (DWA) can no longer be armed. If anti-theft system is already armed, transport mode is
ignored and only accepted after anti-theft system is deactivated.
Transport mode activated in Chorus, Concert, Symphony and Navigation Plus (RNSD with CD) radio
has the following effects.
 Device does not draw any current and cannot be operated.
NOTE:  K-lead adapter VAS 6017B must be used.
cardiagn.com
 Transport mode can be reset in Navigation Plus (RNSE with DVD).
Deactivate transport mode using guided fault finding or guided functions.


12:49:50 AM Page 75
 Service work
 Transport mode, activating/deactivating
Door arrester and lock cylinder: Lubricate
cardiagn.com
Fig. 92: Identifying Greasing Points For Door Latches
 lubricate door latches only at lubrication points shown - arrows -.
 Lubricate lock cylinder.
Plenum chamber cover: Removing
Fig. 93: Identifying Plenum Chamber Cover & Removing Rubber Seal
12:49:50 AM Page 76
 Remove plenum chamber cover rubber seal in direction of - arrow -.

cardiagn.com
On vehicles from VIN >8E Z 5 A 400 001
 Remove plenum chamber cover rubber seal in direction of - arrow -.

Telematics: Emergency battery, replacing
NOTE:  Emergency battery should be replaced very 4 years on vehicles with

Telematics.
Telematics control module is located in right footwell E-box (passenger side, below floor covering).
 Lower A-pillar trim, removing and installing; Floor covering, raising: --> - 70 - INTERIOR TRIM
Fig. 95: Identifying Passenger Side Electronics Box Cover

12:49:51 AM Page 77
 Release passenger side electronics box cover - arrows -.

 Remove Telematics control module from E-box (do not disconnect control module).
Fig. 96: Identifying Screws On Bottom Side Of Telematics Control Module
cardiagn.com
 Remove both screws - arrows - on bottom side of Telematics control module and remove cover.
Fig. 97: Identifying Connector And Emergency Battery

 Disconnect connector - 1 - and remove emergency battery - 2 -.

 Perform installation in reverse order of removal.
Note before disconnecting battery.
WARNING: Activate Telematics control module Service Mode before disconnecting

battery.
Vehicle Diagnostic, Testing and Information System VAS 5051; Guided Fault Finding; Adaptation;
Telephone/Telematics
12:49:51 AM Page 78
NOTE:  Retrieve radio/navigation unit anti-theft coding before disconnecting

battery.
 If battery is reconnected, activate vehicle equipment (radio/navigation,
clock, electric windows, engine) according to operating instructions and
deactivate Telematics control module service mode. Vehicle Diagnostic,
Testing and Information System VAS 5051; Guided Fault Finding;
Adaptation; Telephone/Telematics
Transport protection: Remove front and rear strut transportation protection devices
cardiagn.com
Fig. 98: Identification Tag Attached At Mirror
For some models the front and rear suspension struts have transportation protection devices installed. These
models can be identified by a tag attached at the mirror - arrow -.
 Release coil spring (for example, put vehicle on lift)
NOTE:  It is not necessary to remove the wheels.

 Be careful not to damage surface of coil springs.
Remove transportation protection devices --> Front strut
Front strut
12:49:51 AM Page 79

cardiagn.com
Rear strut


Underbody protection: Visual inspection for damage
 When inspecting visually, observe underbody, wheel housings and sills!
12:49:51 AM Page 80
Winter tires from factory
On vehicles that were delivered from factory with winter tires, check for correct pressure during delivery
inspection.
The excessive speed warning sticker should be placed in drivers field of vision.
Timing belt: Replacing
4-cyl. 5V engines 1.8L Turbo
 Toothed belt, removing and installing --> - 13 - ENGINE - CRANKSHAFT, CYLINDER BLOCK
 Toothed belt, removing and installing: --> - 13 - ENGINE - CRANKSHAFT, CYLINDER BLOCK
cardiagn.com
4-cyl. 4V engines 2.0L TFSI
 Toothed belt, removing and installing: --> - 13 - ENGINE - CRANKSHAFT, CYLINDER BLOCK
6-cyl. 5V engines 3.0L;
 Toothed belt, removing and installing: --> - 13 ENGINE - CRANKSHAFT, CYLINDER BLOCK
Toothed belt change, filling out sticker - all
Fig. 101: Locating Toothed Belt Change Sticker At Rear Of Engine Compartment
 Fill out toothed belt change sticker - 2 - at rear of engine compartment, attach new sticker if necessary.
Spark plugs: Replacing
 Spark plug wrench 3122 B
12:49:51 AM Page 81
Fig. 102: Placing Ignition Coil Puller T40039 On Top Most Thick Rib Of Ignition Coils
 Ignition Coil Puller T40039
cardiagn.com
WARNING: Place Ignition Coil Puller T40039 on top rib - arrow - of ignition coil and
pull this from spark plug. Placing on bottom rib can cause damage.
NOTE:  Plug designation --> -

 28 IGNITION/GLOW PLUG SYSTEM for 1.8 LITER 4-CYL. 5V TURBO
FUEL INJECTION & IGNITION, ENGINE CODE(S): AMB
 28 - IGNITION/GLOW PLUG SYSTEM for 2.0 LITER 4-CYL. 4V TURBO
FUEL INJECTION IGNITION, ENGINE CODE(S): BPG, BWT
 28 IGNITION/GLOW PLUG SYSTEM for 3.0 LITER 6-CYL. 5V FUEL
INJECTION & IGNITION, ENGINE CODE(S): AVK, BGN
 28 - IGNITION SYSTEM for 3.2 V6 4V FUEL INJECTION IGNITION,
ENGINE CODE(S): BKH
 28 - IGNITION/GLOW PLUG SYSTEM for 4.2 LITER V8 4V FUEL
INJECTION AND IGNITION, ENGINE CODE(S): BNS
 28 IGNITION/GLOW PLUG SYSTEM for 4.2 LITER V8 5V FUEL
INJECTION AND IGNITION, ENGINE CODE(S): BHF
4-cyl. 5V engines 1.8L Turbo --> 4-cyl. 5V engines 1.8L Turbo:
4-cyl. 5V engines 2.0L and 2.0L TFSI --> 4-cyl. 5V engines 2.0L and 2.0L TFSI
6-cyl. 3.0L and 3.2L FSI 5V engines --> 6-cyl. engines 3.0L and 3.2L FSI:.
8-cyl. 4.2L MPI 5V engines --> 8-cyl. engines 4.2L MPI.
8-cyl. 4.2L 5V engines (RS4) --> 8-cyl. engines 4.2L (RS4)
12:49:51 AM Page 82
4-cyl. 5V engines 1.8L Turbo:
 Remove engine cover --> Engine cover: Removing.

cardiagn.com
Fig. 103: Identifying Connectors At Spark Plugs
 Remove connector - 1 - at spark plugs.

Spark plugs in cylinder head 30
cover.
4-cyl. 5V engines 2.0L and 2.0L TFSI

12:49:51 AM Page 83
Fig. 104: Identifying Bolts And Connectors

cardiagn.com
cover.
6-cyl. engines 3.0L and 3.2L FSI:

 Remove engine cover (if present) --> Engine cover: Removing.
Right cylinder bank
 Remove upper part of air filter --> 4-cyl. 1.8L 5V Turbo engines:.
12:49:51 AM Page 84

cardiagn.com
cover.
Left cylinder bank

12:49:51 AM Page 85

cardiagn.com
cover.
8-cyl. engines 4.2L MPI
Right cylinder bank
 Remove upper part of air filter --> Air cleaner: Clean air filter housing and replace filter.
12:49:51 AM Page 86

cardiagn.com
cover.
Left cylinder bank
Fig. 109: Removing Cover Upward

 Remove cover upward.
12:49:51 AM Page 87

cardiagn.com


cover.
12:49:51 AM Page 88
8-cyl. engines 4.2L (RS4)
Right cylinder bank
 Remove upper part of air filter --> Air cleaner: Clean air filter housing and replace filter.
cardiagn.com

cover.
Left cylinder bank
12:49:52 AM Page 89

cardiagn.com


cover.
12:49:52 AM Page 90
Headlights: Aiming using Hella Universal Beamsetter IV
Service
Align vehicle headlights using the Hella Universal Beamsetter IV VAS 5107 and the following procedure:
Additional instructions and diagrams Instruction Manual for the Hella Beamsetter Series IV
cardiagn.com
Fig. 115: Identifying Floor Surface Specifications For Vehicle
 Position vehicle on a flat floor surface that meets the following (ISO 10640) specifications:
 0.5mm or less slant from front wheel to back wheel of the Hella Universal Beamsetter IV VAS 5107 - A -
.
 1mm or less slant per meter for the length of the vehicle - B -.
 Clean headlight lenses.

 Adjust vehicle tire pressure to specifications.
Have a second technician sit in the drivers seat while aligning the headlights.
 Bounce front and rear of vehicle up and down several times to settle vehicle suspension.
Setting low beam alignment of drivers side headlight
 Move Hella Universal Beamsetter IV VAS 5107 into position in front of the vehicle so it is aligned with
the vehicle and Hella Universal Beamsetter IV VAS 5107 is 30 to 70cm (12 to 28 in.) from the drivers
side headlight.
 Switch headlights ON in low beam position.
 Align Hella Universal Beamsetter IV VAS 5107 so it is centered on the headlight (align vertically then
horizontally).
NOTE:  Use the arrows on the Hella Universal Beamsetter IV VAS 5107 housing as
12:49:52 AM Page 91
a guide.
 You may want to use a straight edge or tape measure, because alignment
must be within 3cm (1.2 in.) of the center of the headlight.
 Without moving the Hella Universal Beamsetter IV VAS 5107 , slide Broad-
band sight toward center of vehicle (Broad-band sight can also be moved
up and down for a better position).
Use Broad-band sight to make final alignment of Hella Universal Beamsetter IV VAS 5107 to vehicle by:
 Loosening hand-wheel that locks column in place.

 Sighting down through the slit in the Broad-band sight and rotating Hella Universal Beamsetter IV VAS
5107 and column until two similar points on vehicle are aligned
NOTE:  Try using corners of the headlight housings or two screws that are the
same height and as far apart as possible on the vehicle.
cardiagn.com
 Carefully tighten hand wheel without changing Hella Universal Beamsetter
IV VAS 5107 position.
 Set Inclination to 1.0 %.
 Set Hella Universal Beamsetter IV VAS 5107 "Scaled wheel" to the proper
low beam inclination %.
 Adjust height (vertical) alignment first. Turn headlight height adjuster
screw to align the upper edge of the flat portion of the beam with the
center horizontal line of the grid on the Hella Universal Beamsetter IV VAS
5107 pattern screen.
NOTE:  VOL is the correct beam pattern for both right and left headlights.
Fig. 116: Identifying Specifications For Drivers Side Headlight Beam Angle
 Adjust lateral (horizontal) alignment of drivers side headlight so that the peak (highest point) of the
headlight beam pattern aligns with the right edge of the target box of the grid on the pattern screen (it
12:49:52 AM Page 92
should match the VOL pattern shown on the Hella Universal Beamsetter IV VAS 5107 ).
NOTE:  If the height alignment changed, readjust.
Checking drivers side headlight high beam alignment
 Switch headlights ON in high beam position.

 Realign Hella Universal Beamsetter IV VAS 5107 with the high beam headlight if necessary.
cardiagn.com
Fig. 117: Identifying Beamsetter "Scaled Wheel" At 0%
 Set Beamsetter "Scaled wheel" to 0%.

 Cover low beam lamp (use hand or small piece of cardboard) and check that the "hot spot" of high beam
pattern is centered on the square target box of the pattern screen.
NOTE:  High beam pattern is built into the reflector design and cannot be adjusted
separately.
If high beam pattern is way out of adjustment:
 Inspect for reflector damage.

 Replace reflector if needed.
NOTE:  Always align headlight in the low beam position.
Aligning fog lamp
 Switch fog lamps ON.

 Align Hella Universal Beamsetter IV VAS 5107 with fog lamp (make sure it is between 30 and 70cm
from the fog lamp lens).
12:49:52 AM Page 93
Fig. 118: Identifying Hella Universal Beamsetter IV VAS 5107 Scaled Wheel At 1.4%
 Set Hella Universal Beamsetter IV VAS 5107 scaled wheel to 1.4%.
cardiagn.com
Adjust fog lamp so the top of the beam pattern aligns with the centerline of the target grid on the beam pattern
screen.
Passengers side headlight, alignment
 Move Hella Universal Beamsetter IV VAS 5107 to the passenger side of the vehicle and follow the same
procedures to align the Hella Universal Beamsetter IV VAS 5107 to the headlamp.
 Align headlight low beam, check high beam and align fog lamp.
NOTE:  Make sure to reset the Hella Universal Beamsetter IV VAS 5107 "Scaled
wheel" to the proper setting each time you change from low beam to high
beam or to fog lamp.
 Ensure that headlights and vehicle body are clean and free of fingerprints.
RAPGARD: Inspection, removal and disposal
From my 2002
Service
Within 48 Hours after arrival at Dealer:
Inspection
 Inspect RAPGARD for damage or peeling.
If RAPGARD is disturbed (dented, scratched, etc.):
 You must note the damage on the Carrier Delivery Receipt, including damage type, extent and location.
12:49:52 AM Page 94
Failure to note damage on the Carrier Delivery Receipt will result in non-payment of the repair.
NOTE:  RAPGARD must be removed from the vehicle no later than six months
after application. See sticker (location on vehicle body varies) for detailed
information.
Within 72 Hours prior to delivery to the Customer:
 Remove RAPGARD from vehicle.

 Wash vehicle exterior.
 Inspect paint surfaces, moldings and glass.
 Protect the paint surface of all new vehicles by applying 3M Perfect-It Paste Wax (3M Part No. 39526) or
equivalent.
Removal
cardiagn.com
 Vehicle must be at room temperature.
 The ideal body surface temperature for RAPGARD removal is 60 ° F (15.5 ° C) to 80 ° F (26.6 ° C).
If body surface temperatures are below 60 ° F (15.5 ° C) or above 80 ° F (26.6 ° C) then:
 Removal procedure should be performed indoors after surface temperatures have been allowed to
stabilize within the given range.
 Rinse vehicle thoroughly with water to remove surface dirt or dust and to help stabilize body surface
temperatures.
 Starting at the corners of each panel, carefully remove RAPGARD from vehicle.
RAPGARD, paint inspection after removal
 Inspect painted surfaces under one of the following lighting conditions:
 Indoors under fluorescent lighting.

 Outdoors under bright sunlight.
Important!
If any defects on the exterior have been identified (scratches, dings, dents and other types of body damage):
 Contact your Service Manager and arrange to repair defects immediately.
NOTE:  After removal of RAPGARD, some vehicles may exhibit temporary paint
discoloration or paint swelling (caused by trapped moisture under the
RAPGARD).
12:49:52 AM Page 95
 This temporary swelling is caused by the paint finish absorbing moisture

trapped under the RAPGARD film.
 This swelling will disappear with exposure to the sun or heat lamps within
2 - 3 hours. Severe Paint swelling may require 2 - 3 days to recover.
DO NOT buff or refinish paint for this condition!
Adhesive residue removal
WARNING: Always read and follow manufacturer Cautions and Warnings regarding
use of product.
If RAPGARD adhesive residue remains on paint finish, remove with a non-abrasive polishing product such as,
(3M Part No. 5995) light colors or (3M Part No. 5996) dark colors or equivalent.
cardiagn.com
Thick lines of adhesive residue can be removed with general purpose adhesive cleaner (3M Part No. 08987-
aerosol, or Part No, 08984-qt. can) or equivalent.
NOTE:  Paint discoloration (looks like shaded or dark magic marker lines) can be
removed with a heat gun using the following procedure:
 Hold heat gun approximately 3 in. away from affected paint surfaces and
apply heat using slow oscillating motions until discoloration is gone.
 If discoloration remains, wipe the heated area with Isopropyl alcohol and
repeat procedure to increase surface drying.
Important!
After inspecting and removing RAPGARD, washing vehicle, inspecting and repairing any defects in paint
surfaces, moldings and glass:
 Protect the vehicle paint surface by applying 3M Perfect-It Paste Wax (3M Part No. 39526) or equivalent.
RAPGARD Disposal
RAPGARD can be disposed as normal paper waste. If unsure about proper disposal procedures in your area,
check local regulations.
TYPE PLATE / VEHICLE IDENTIFICATION NUMBER (VIN)
Type plate / Vehicle Identification Number (VIN)
Meaning of Vehicle Identification Number (VIN):
WAU ZZZ 8E Z 1 A 000 520
12:49:52 AM Page 96
Manufacturer- Filler Model Filler Model year Production Serial number

code characters characters 2001 location
Vehicle data sticker
The vehicle data sticker is in the customers service schedule and in the vehicle in the spare wheel recess or on
the luggage compartment floor.
NOTE:  Service plan vehicle data plate is located in spare wheel well on "Avant
vehicles". Vehicle data plate that remains in vehicle is located under rear
seat bench.
cardiagn.com
Fig. 119: Identifying Vehicle Data Sticker
Sticker contains the following vehicle data:
Engine code and engine identification
NOTE:  The "engine code" is on the vehicle data sticker in the service schedule
and in the spare wheel recess or on the luggage compartment floor.
4-cyl. - 2V gasoline engine:
12:49:52 AM Page 97
Fig. 120: Identifying Engine Number Is Located At Left Of Engine/Transmission Connecting Point
Engine number ( "engine code" and "serial number" ) is located at left of engine/transmission connecting point.
cardiagn.com
4-cyl. - 5V gasoline engine 1.8L Turbo:

4-cyl. - 5V gasoline engines 2.0L:
12:49:52 AM Page 98

cardiagn.com
4-cyl. - 2.0 TFSI engines:

12:49:52 AM Page 99
Fig. 124: Identifying Engine Code Stamped On Right Inner Side Of Cylinder Block
Engine number ( "engine code" and "serial number" ) is stamped on right inner side of cylinder block between
cylinder head and hydraulic pump.
cardiagn.com
Fig. 125: Identifying Engine Number On Left Front Of Cylinder Block

Engine number ( "engine code" and "serial number" ) is located at left front of cylinder block - arrow -.
V8 gasoline engines:
12:49:53 AM Page 100


cardiagn.com
V8 gasoline engines RS4
Fig. 127: Locating Engine Number

VEHICLE, LIFTING
Vehicle, lifting
WARNING:  Before driving on to a hoist ensure there is sufficient clearance

between low lying vehicle components and hoist.
 Before driving a vehicle onto a lifting platform it must be ensured
that the vehicle weight does not exceed the permissible lifting
capacity of the platform.
 Vehicle may only be lifted at points indicated in illustration in order
to avoid damaging vehicle floor pan and to prevent vehicle from
12:49:53 AM Page 101

tipping.
 Never start engine and engage a gear with vehicle lifted so long as
even one wheel has contact with the floor. There is a risk of an
accident if this is not observed!
 If work is to be performed under vehicle it must be supported by
suitable stands.
Floor jack
Always use a suitable rubber or wooden block between the jack and the vehicle.
A floor jack must be attached only at the mounting points depicted in the illustration.
Do not lift the vehicle at the engine oil pan, transmission, or on front or rear axles as serious damage may result.
cardiagn.com
Lifting points for lifting platform and floor jack
Fig. 128: Identifying Front Side Member Vertical Stiffener

Front:
12:49:53 AM Page 102

Fig. 129: Identifying Rear Side Member Vertical Stiffener

Rear:
cardiagn.com
TOW STARTING/TOWING
Tow starting/towing
 Attach tow rope or bar only at following eyes:
Front towing eye
Fig. 130: Identifying Front Towing Eye


Rear towing eye
12:49:53 AM Page 103

Fig. 131: Identifying Rear Towing Eye

cardiagn.com
Remove towing eye after use and return to vehicle tool kit storage compartment. Towing eye must always be in
vehicle.
NOTE:  The tow-rope should be able to stretch to reduce the risk of damage to
both vehicles. It is advisable to use synthetic fiber ropes or ropes of
similar elastic material only. However, it is safer to use a tow-bar!
 Avoid excessive towing effort and do not jerk. During towing operations
on unsurfaced roads there is always a danger that the attachment points
will be overstressed and damaged.
 Vehicle towing should only be done if it is not possible to start the engine
with the starting assist cable.
If the vehicle must ever tow or be towed, observe the following:
 Regulations concerning towing must be observed.

 Both drivers must be familiar with the specifics of towing procedures. Inexperienced drivers should not
attempt to tow start or tow.
 When using a tow rope the driver of the towing vehicle must engage the clutch very gently when moving
off and changing gear.
 The driver of the vehicle being towed must ensure that the tow rope is always taut.
 The emergency lights must be switched on both vehicles - unless local regulations differ.
 The ignition must be switched on, so that the steering wheel is not locked and the turn signals, horn,
windshield wipers, and windshield washer system can be operated.
 Since the brake booster only works with the engine running, the brake pedal must be stepped on with
12:49:53 AM Page 104

substantially more force when the engine is switched off.

 With the engine switched off, the power steering also does not work, increasing the amount of steering
effort.
 Without lubricants in the manual transmission and/or automatic transmissions the car may only be towed
with raised drive wheels.
When towing vehicles with manual transmission, observe the following:
 Before tow starting, push in clutch pedal and hold, and select gear 2 or 3.
 When both vehicles are moving, release clutch pedal.
 As soon as engine starts, depress clutch and move gear stick into neutral to avoid running into the towing
vehicle.
cardiagn.com
NOTE:  Vehicles with catalytic converter (gasoline engine only) must not be
started when the catalytic converter is at operating temperature and
pulling the vehicle over a longer distance of more than 50 m. Otherwise
unburned fuel may pass into the catalytic converter and cause damage.
 Tow starting vehicles with an automatic transmission is for technical
reasons not possible.
When towing vehicles with front wheel drive and automatic transmission, observe the following:

For longer distances, the front end of the vehicle must be raised.
Reason: When the engine is not running the transmission oil pump is not working and the transmission is not
adequately lubricated for high speeds or long distances.
Using a breakdown vehicle, the vehicle may only be towed suspended at the front.
Reason: If given a rear suspended tow, the drive shafts turn backward. This would cause the planetary gears in
the automatic transmission to achieve such high RPM that the transmission would be heavily damaged within a
very short time.
When towing vehicles with all wheel drive and manual transmission, also observe the following:

12:49:53 AM Page 105

Using a breakdown vehicle the vehicle may be towed suspended at front or rear.
NOTE:  If normal towing of the vehicle is not possible, the vehicle must be
When towing vehicles with all wheel drive and automatic transmission, also observe the following:

The vehicle must not be towed by a tow truck with front or rear axle raised.
NOTE:
cardiagn.com
 If normal towing of the vehicle is not possible, the vehicle must be
VEHICLE CHECKS WITHIN INSPECTION AND SERVICE FRAMEWORK
Vehicle checks within inspection and service framework
For vehicle checks, we recommend interactive acceptance VAS 5000 and performance test stand V.A.G 1858.
Brake check
Information for checking brakes on front and all wheel drive vehicles is in the corresponding brake system
repair manual.
Performance check
Perform performance check on performance test stand recommended by Audi. The corresponding correction
factors for automatic transmissions and all wheel drive are provided in these test stands. Vehicles with all wheel
drive may only be tested on a four-wheel performance test stand. The four-wheel performance test stand V.A.G
1858 has movable rollers in order to be able to test vehicles with different axle spacing.
Tachometer check
With the tachometer test, the vehicle wheels are driven. Vehicles with all wheel drive may only be tested on a
four-wheel test stand.
Shock absorber check
Information on testing shock absorbers can be found in the suspension repair manual.
12:49:53 AM Page 106

002 Maintenance

Uploaded by

Copyright:

Available Formats

002 Maintenance

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

002 Maintenance

Uploaded by

Copyright:

Available Formats

2005 Audi A4 Quattro

Maintenance Maintenance Procedures - Cabriolet

Maintenance Procedures - Cabriolet

NOTE:  Some engines listed below are for European models.

1*) Engine code AVF 3.0 Nm

OIL CHANGE SERVICE

Oil change service

 Central locking, remote control operation, comfort closing

 39 - FINAL DRIVE, DIFFERENTIAL for 5 SPD. AUTOMATIC TRANSMISSION 01V

Continuously Variable Transmission (CVT)

--> - 39 - FINAL DRIVE, DIFFERENTIAL

Battery with "magic eye"

Fig. 2: Identifying The Visual Indicator

 Switch ignition off.

Fig. 3: Identifying The Visual Indicator

 Check electrolyte level at visual indicator - arrow -.

NOTE:  Observe before disconnecting battery --> Note before disconnecting

Battery sealing plugs

replaced! --> - 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL

Valve-regulated lead acid battery or absorbed glass mat (AGM) battery

Necessary test equipment

 Digital multimeter V.A.G 17.5

Fig. 4: Special Tool - Multimeter V.A.G 1526 A

WARNING: Always follow procedure exactly, otherwise measured values could be

Battery: Ensure battery cable fits securely

Fig. 5: Locating Battery Terminals On Battery

NOTE:  Observe before disconnecting battery --> Note before disconnecting

Fig. 6: Locating Battery Terminals On Battery

Battery: Perform battery load test

Battery load test indicates battery condition.

Special tools, testers, and measuring equipment

Fig. 7: Battery VAS Tester

 Battery tester VAS 5097 A

Perform battery load test

 Switch ignition off.

The clamps must make good contact with battery poles.

Tester display during battery load test

Note following tester evaluations:

 Replace battery. --> - 27 BATTERY, STARTER, GENERATOR, CRUISE CONTROL

Regarding battery load test:

Brake fluid level, dependent on lining wear: Check

Fig. 8: Identifying Fluid Level

 Fluid level must be at MAX mark

 Always check fluid level in conjunction with brake pad wear:

Fig. 9: Identifying Fluid Level

Brake fluid: Changing

Special tools, testers, and measuring equipment

 VAS 52.4 Brake filling and bleeding tool

 Observe waste disposal regulations!

Observe operating instructions for VAS 52.4 or for V.A.G 1869 !

Fig. 12: Identifying Brake Fluid Reservoir Cap

 Remove brake fluid reservoir cap - 1 -.

 Remove brake fluid reservoir plug - arrow -.

Courtesy of VOLKSWAGEN UNITED STATES, INC.

WARNING: Do not reuse, (used) extracted brake fluid.

 Install adapter - 1 - to brake fluid reservoir.

Vehicles with manual transmission:

 Pull cover cap off clutch slave cylinder bleed screw.

Continued for all vehicles: