Audi A4 (B6, B7) Repair Manual: 2002-2008 - Excerpt

A408_03.fm Page 50 Friday, October 8, 2010 1:22 PM

03-50

Maintenance

Air filter, replacing (6-cylinder) 3.2L

½ Open retaining clips (4) and disconnect air intake hose. A00-10094

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Unclip fuel line retaining clip (3).

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Release hose clamp and disconnect hose (1).

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Remove mounting screws (2) for upper air filter housing.

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Remove upper part of air filter from bracket and pivot toward engine.

½ Remove air filter element (13) from lower air filter housing (15). 1. Screw 2. Air duct 3. Screw

A24-10087

4. Air guide 5. Air guide 6. Strainer 7. O-ring 8. Air intake hose 9. Rubber grommet 10. Expanding anchor 11. Screw 12. Upper filter housing 13. Air filter element 14. Rubber grommet 15. Lower air filter housing

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Clean filer housing and install new air filter. • Make sure air filter is correctly installed and seated into housing.

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Install in reverse order of removal.

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Maintenance

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Brake pads, checking

03

UNDER CAR MAINTENANCE Brake pads, checking Periodic maintenance of the brake system includes inspection of front and rear brake for pads thickness. To accurately check inner and outer brake pad thickness, it is necessary to remove the wheels. Checking the outer pad thickness can be accomplished without removing the wheels. Vehicles covered by this manual may use wheel locks. The key for the locks is usually stored in the vehicle tool kit. See Tire and wheel service in this repair group. If using a lift or hoist, remove tool kit before raising vehicle.

VJ0646005

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Remove wheel bolt caps and alloy wheel center cap as required. Before removing a wheel, mark it’s position in relation to brake rotor so wheel can be reinstalled in same position.

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Loosen wheel bolts slightly before raising vehicle.

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Raise vehicle and support safely. See Lifting Vehicle in this repair group.

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Remove wheel bolts and wheel.

½ Measure inner and outer front brake pad thickness (distance between arrows).

½ Alternatively, looking through brake caliper opening: Measure inner and outer rear brake pad thickness (distance between arrows). Wear limit VJ0646008

Rear brake pad, minimum thickness (without backing plate)

2 mm (0.079 in)

When brake pads have reached their wear limit, replace them. When replacing brake pads, be sure to inspect brake discs (rotors) for wear. See 46 Brakes–Mechanical.

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Install wheel noting reference mark made on removal. Install wheel bolts and torque to specification in proper sequence. Tightening torque Wheel bolts to hub

120 Nm (89 ft-lb)

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Install wheel bolt caps and alloy wheel center cap as required.

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Lower vehicle. Stow jack, tools, and locking wheel bolt key in trunk.

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Maintenance

Brake system, visual inspection Brake system, visual inspection Check power brake servo (booster) and brake master cylinder, ABS / ESP hydraulic unit, front and rear brake calipers and hoses, and brake lines for leaks and damage. Also inspect brake cables and parking brake for proper operation and damage. Note the following: • Brake hoses must not be twisted. • Brake hoses must not touch any part of the vehicle when steering is at full lock and suspension is at the limits. • Check hoses and lines for porosity, deterioration and chafing. • Check brake connections and attachments for correct seating, leaks and corrosion. Correct problems noted during the visual inspection immediately. For parking brake adjustment, see 46 Brakes–Mechanical.

Drive axles, checking boots

½ Inspect front outer constant velocity (CV) joint boots (arrow) for leakage, cuts and damage. Ensure that boots are correctly seated. Right front outer shown, left front outer is similar.

AT0603082.tif

½ Inspect front inner constant velocity (CV) joint boots (arrow) for leakage, cuts and damage. Ensure that boots are correctly seated. Right side inner is shown, left side inner is similar. AT0603085.tif

½ On quattro equipped vehicles, inspect rear outer (arrow) and inner constant velocity (CV) joint boots for leakage, cuts and damage. Ensure that boots are correctly seated. Right rear is shown, left rear is similar. AT0603086.tif

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If inspection of drive axle components reveals wear, leakage or damage as outlined above, replacement is indicated. See 40 Front Suspension and Drive Axles for suspension component replacement.

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Maintenance

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Fluid and exhaust leaks, visual inspection The engine and transmission, along with components in the engine compartment should be visually inspected for leakage and damage. Fluid leaks attract dust and dirt making them somewhat easier to spot. A visual inspection should include: • Engine • Transmission (manual and automatic) • Fuel system • Cooling and heating systems • Brake system • Exhaust system Check engine and components in engine compartment from above and below for leaks and damage. Check hoses, pipes and connections for routing, signs of leaks, abrasions, chafing, porosity and brittleness. A small amount of dampness may be considered normal in some cases, especially around axle and pulley seals since the contained fluid helps the seal work properly. Many expensive repairs can be avoided by prompt repair of minor fluid leaks. If fluid losses are greater than can be reasonably expected, determine cause and repair. See appropriate section for additional information.

Front suspension components, checking A00-10097

When vehicle is safely raised and wheels are off the ground, inspect rubber boots protecting suspension and steering and drive axle components as noted.

½ Inspect lower ball joint boots (arrows) for leakage, cuts and damage. Ensure that boot is correctly seated.

½ Inspect lower ball joint axial play: • Move wheel up and down (lower arrow). There should be no noticeable or visible up/down “play” in joint (upper arrow). A00-10096

• Observe lower ball joint while checking. • Allow for any wheel bearing or upper strut mount “play”.

03

Fluid and exhaust leaks, visual inspection

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Maintenance

Fuel filter, replacing

½ Inspect outer tie rod end boots (arrow) for leakage, cuts and damage. Ensure that boots are correctly seated. Tie rods are equipped with similar boots at their inner junctions which should be inspected in the same manner. Use a mirror for inspection if necessary.

A02-0041

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Check that lock nut (1) is tight. Tightening torque Lock nut on tie rod

40 Nm (30 ft-lb)

If inspection of front suspension components reveals wear, leakage or damage as outlined above, replacement is indicated. See 40 Front Suspension and Drive Axles and 48 Steering for Underbody, visual inspection The factory recommends that underside of vehicle be inspected for damage. Damage can be caused by normal wear and tear or by driving over road debris. Whenever vehicle is raised on a lift or a hoist, it is advisable to visually inspect underbody, wheel wells, and sill/rocker panels for damage to underbody sealants and coatings. Inspection should also be made after major repairs to vehicle systems. Promptly repair any damage or defects found. Use wax-based or tarbased anti-corrosion compounds as specified. Do not use oil-based anti-corrosion sprays due to possible incompatibility with factory applied protection. Check with an authorized Audi dealer parts department for appropriate sealing compounds. Inspect underbody components such as plastic panels to be sure they are securely attached and there is no fluid leakage anywhere.

Fuel filter, replacing Fuel filters do not have a specific replacement interval but should be replaced as conditions or situations dictate. See 20 Fuel Storage and Supply.

Tire and wheel service Tire maintenance Tire maintenance should be carried out at least as often as every maintenance service. Pressures should be checked more often and it should be remembered that pressures will change with seasonal temperature changes. A “walk around” visual vehicle inspection including the tires, is advisable before vehicle operation. Check tire pressures when the tires are cold due to the normal pressure rise associated with heat generated by driving. Tire pressures vary between vehicle with different engine types and between different model years. Refer to data label on driver’s side “B” pillar for proper inflation pressures. See Identification Plates and Labels at the beginning of this section. Be sure to also check spare tire pressure. Always replace dust caps on tire valves when checking tire pressures. If valve extensions are used (as on steel wheels and

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BentleyPublishers .com

Audi A4 (B6, B7) Service Manual: 2002-2008 1.8L turbo, 2.0L turbo, 3.0L, 3.2L including Avant and Cabriolet

Price: $149.95 Bentley Stock Number: A408 Publication Date: 2010.dec.20 ISBN: 978-0-8376-1574-5 Hardcover, 8 3/8 in. x 11 in. Case quantity: 1 1430 pages, 2610 photos, illustrations and diagrams The Audi A4 Service Manual: 2002-2008 contains in-depth maintenance, service and repair information for Audi A4 models from 2002 to 2008 built on the B6 or B7 platforms. Service to Audi owners is of top priority to Audi and has always included the continuing development and introduction of new and expanded services. Whether you’re a professional or a do-it-yourself Audi owner, this manual will help you understand, care for and repair your Audi.

Technical model introduction information in full color 02 Product Familiarization

Technical features: • Covers Audi A4 Sedan, A4 Avant (station wagon) and A4 Cabriolet models including quattro versions. (Does not cover S4 or RS4 sport models.) • Audi A4 product familiarization section in full color, highlighting technical features, year-to-year changes and application information. • Maintenance procedures from routine oil changes to brake pad and rotor inspection and replacement. • Engine and cylinder head service, including timing belt and brake booster vacuum pump replacement. • Component testing, removal and installation for engine lubrication, cooling, turbocharger and exhaust systems. • Fuel supply system service, including fuel pump delivery volume test, EVAP system component locations and electronic power control (EPC). • Fuel injection and ignition system component identification and technical data, including intake manifold removal and installation. • Drivetrain maintenance, troubleshooting, adjustment and repair, including hydraulic clutch, gearshift linkage and axles. • Repair information for ABS brake systems. • Suspension component replacement, including struts, stabilizer bar, multi-link elements and wheel bearings. • Body adjustment and repairs, including doors, fenders, front radiator support, dashboard, sunroof and seats. • Heating and air-conditioning repair, including A/C component replacement such as evaporator housing. • Includes factory wiring diagrams, component locations and a general explanation of electrical circuitry. • Audi OBD II diagnostic trouble code section, including SAE and manufacturer defined P-codes.

Preventative maintenance procedures, including brake system inspection and service 03 Maintenance

Wiring diagrams and component locations EWD Electrical Wiring Diagrams

Engines covered: 1.8L turbo gasoline (engine code: AMB) 2.0L turbo FSI gasoline (engine codes: BGP, BWT) 3.0L gasoline (engine codes: AVK, BGN) 3.2L gasoline (engine codes: BKH)

Transmissions covered: 5-speed Manual (transmission codes: 012, 01W, 01A) 6-speed Manual (transmission codes: 01E, 01X, 02X) 5-speed Automatic (transmission code: 01V) 6-speed Automatic (transmission code: 09L) CVT (transmission code: 01J)

Bentley Publishers, 1734 Massachusetts Avenue, Cambridge, MA 02138-1804 USA Tel: 617-547-4170 • Toll Free: 800-423-4595 • Fax: 617-876-9235 http://www.bentleypublishers.com/contact-sales bentley_a408_new.product.announcement.pdf