Audi A4 (B6, B7) Service Manual: 2002-2008 - Complete Index

A408_index.fm Page 1 Wednesday, October 13, 2010 9:38 AM

INDEX WARNING Your common sense, good judgement and general alertness are crucial to safe and successful service work. Before attempting any work on your Audi, be sure to read 00 Warnings and Cautions and the copyright page at the front of the manual. Review these warnings and cautions each time you prepare to work on your car. Please also read any warnings and cautions that accompany the procedures in the manual.

A

Antilock brakes (ABS) 02-16, 45-1 components Bosch 5.7 45-6 Bosch 8.0 45-9 diagnosis 45-4 impulse wheel front 45-12 rear (FWD) 45-13 rear (quattro) 45-16 wheel speed sensors 45-11 Anti-theft 96-29 A-pillar connector left 97-12 right 97-11 trim 70-23

ABS see Antilock brakes (ABS)

Arm rest 70-15

Acceleration sensors ABS 45-6

Ashtray front 70-16

Accelerator pedal assembly 20-28

Automatic transmission 02-12 ATF 37-3 codes 37-1 CVT ATF 37-5 identification 03-8 selector mechanism 37-15 shift lock 37-16 see also Continuously variable transmission (CVT)

Accessory belt 03-36 Air-conditioning (A/C) air distribution 87-7 blower motor 87-12 capacities 87-4 components 87-9 compressor 87-13 controls and power supply 87-5 dust and pollen filter 03-59 evaporator housing 87-14 flap motors 87-7 refrigerant and refrigerant oil 87-4 repairs 87-12 troubleshooting 87-2 Air filter 03-46 Airbags 02-19, 03-58, 69-10 Alignment 44-5 Alternator (generator) belt 03-36 removing and installing 27-10, 27-13, 27-15, 27-17 Aluminum body panels 55-1 Antenna 91-3 Antifreeze 03-27, 19-5

B Back-up lights manual transmission 34-15 Balance shaft 02-8, 17-9 Battery 27-3 service 03-33 Belt accessory 03-36 timing 03-41, 13-2, 13-10, 13-17 Bi-xenon 94-4, 94-10, 94-17, 94-19, 94-21, 94-25, 94-28 Bleeding brakes 03-30 Blower motor 87-12

Body aluminum panels 55-1 Cabriolet AppendixA-2 dimensions 02-4 front fender 50-4 grill 55-6 overview 02-18 wheel housing liner 66-1 see also Trim B-pillar trim 70-25 Brake booster vacuum pump 15-17 Brake fluid 47-1 bleeding 03-30 level 03-29 Brake light switch 46-21 Brakes 02-16 antilock 45-1 bleeding 03-30 booster 47-3 vacuum pressure sensor 47-8 vacuum pump 47-7 caliper front 46-3, 46-6, 46-9 rear 46-15, 46-17 inspection 03-51 master cylinder 47-3 pads and discs checking 03-51 parking brake 46-20 specifications front 46-1 rear 46-2 troubleshooting 47-1 vacuum pump 47-7 see also Antilock brakes (ABS) see also Brake fluid Bulbs exterior see Headlight component and Taillight component diagrams in 95 Exterior Lights Bumpers front 63-1 rear 63-7 Bus systems 02-22, 9-2

C Caliper front 46-3, 46-6, 46-9 rear 46-15, 46-17 Camshaft sensor 28-7, 28-12

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A408_index.fm Page 2 Wednesday, October 13, 2010 9:38 AM

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INDEX CAN-bus 02-22, 9-2

Disc brakes see Brakes

CD changer 91-3

Convertible top 61-3, AppendixA-12 component locations AppendixB-4 emergency release AppendixB-3 electrical system 61-5, AppendixA-56 hydraulic system 61-11, AppendixA-30

Center brake light 94-40

Coolant see Engine cooling system

Center console 70-11 switches 96-21

Coolant pump removing and installing 19-7, 19-11, 19-23, 19-32

Central locking service notes 57-7

Cooling system see Engine cooling system

Chain, timing 02-11

C-pillar trim 70-27

Door check strap and hinge lubrication 03-59 component carrier 57-6 courtesy light 96-8 front 57-1 handle 57-8 rear 57-2 trim 70-17

Child seat anchor 69-1

Crankshaft pulley 13-4, 13-6, 13-19

Climate control see Air-conditioning (A/C)

Cruise control 27-1 stalk switch 96-16

Catalytic converter 26-3

Clutch bleeding 30-4 components 5-speed 30-16 6-speed 30-18 hydraulics 30-2 repairs 30-16 self-adjusting (SAC) 30-21 Coil see Ignition coil Coil spring front 40-3 rear 42-3 Component locations (electrical) 97-3 Compression test 15-2 Compressor see Air-conditioning (A/C)

Door lock 57-7 Door panel 70-17 Door window see Window D-pillar trim 70-18

CV joint boot checking 03- 52 front 40-17 rear 45-15

Drive axle boot checking 03-52 front 40-17 rear 42-7

CVT 02-13 ATF capacity 37-2 level 37-5 Cylinder head 15-4, 15-8, 15-13, 15-15 Cylinder head cover 15-5, 15-10 Cylinder leak-down test 15-3

Drive belt 03-36 Driver information display 90-1 DTC access OBD-1 P-codes OBD-2 Dust and pollen filter 03-59

E D

Constant velocity (CV) joint see CV joint

Dashboard 02-24 air outlets 87-7 driver storage compartment 70-9 end trim 70-7

Continuously variable transmission (CVT) 02-13 ATF capacity 37-2 level 37-5

Dome light 96-5

Curb weight position 40-1

Console, center 70-11

Continuity 9-5

DLC 24-2, OBD-1

Data link connector (DLC) 24-2, OBD-1 Diagnostic trouble code (DTC) access OBD-1 P-codes OBD-2 Differential oil 39-2 Dimensions 02-4

E-box (electronics box) 97-11 ECM (engine control module) 24-5 EDL (electronic differential lock) 45-2 Electrical system A-pillar connector stations left 97-12 right 97-111 component locations 97-3 fuses 97-11 grounds 97-36 troubleshooting 9-3 wiring diagrams EWD-8

A408_index.fm Page 3 Wednesday, October 13, 2010 9:38 AM

INDEX WARNING Your common sense, good judgement and general alertness are crucial to safe and successful service work. Before attempting any work on your Audi, be sure to read 00 Warnings and Cautions and the copyright page at the front of the manual. Review these warnings and cautions each time you prepare to work on your car. Please also read any warnings and cautions that accompany the procedures in the manual.

Electrolyte 03-33, 27-5 Electronic braking control (EBC) 45-2 Electronic differential lock (EDL) 45-2 Electronic immobilizer 96-29 Electronic stabilization program (ESP) 02-16, 45-2 Electronic power control (EPC) 02-11, 20-37 Electronics box (E-box) 97-11 Emergency flasher switch 96-21 Emergency convertible top AppendixVB-3 sunroof closing 60-3

Engine cooling system antifreeze concentration 03-27,19-5 bleeding 19-6, 19-9, 19-19, 19-29 capacities 03-27, 19-1 coolant level 03-27 coolant pump 19-7, 19-11, 19-23, 19-32 draining, filling 19-6, 19-9, 19-19, 19-29 hoses, inspecting 03-29 pressure testing 19-4 thermostat 19-4, 19-16, 19-28, 19-38 radiator 19-8, 19-12, 19-24, 19-34 troubleshooting 19-3 Engine lubrication components see Lubrication system diagrams in 17 Engine–Lubrication System oil service 03-20 Engine management 02-5 applications 24-2 components see Engine compartment diagrams in 24 Fuel Injection diagnostics 24-2 electronic throttle control (EPC) 20-37 engine control module (ECM) 24-5 engine coolant temperature (ECT) sensor see Engine compartment diagrams in 24 Fuel Injection evaporative control (EVAP) 20-34 ME7.1.1 02-10 ME7.5 02-6 MED 9.1 02-7 Motronic 24-1 secondary air injection 26-36 Siemens 02-11 see also Ignition system

Engine 02-5 accessory belt 03-36 applications table 02-5 balance shaft 02-11 compartment 03-16 covers 03-18 identification 03-6 fluid leaks 03-20 speed sensor 28-5, 28-11 technical data 02-5 timing belt 03-41

EPC (electronic power control) 02-11, 20-27

Engine control module (ECM) 24-5, 26-3

Exhaust system installation details 26-8, 26-12, 26-19, 26-29 see also Exhaust system diagrams in 26 Exhaust System

Engine coolant temperature (ECT) sensor 24-4, 24-5, 24-7, 24-8

ESP (electronic stabilization program) 02-16, 45-2 Evaporative control (EVAP) 20-34 Evaporator see Air-conditioning (A/C) Exhaust manifold 21-10

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F Fender, front 50-4 Final drive oil 39-2 Filter air 03-46 dust and pollen 03-59 fuel 03-54 oil 03-22 Fluid leak engine compartment 03-20 Flywheel 30-16, 30-18 Foglight 94-30 Footwell light 96-9 Front suspension 02-14 codes 44-2 coil spring 40-3 control arms 40-5 curb weight position 40-1 stabilizer bar 40-16 strut assembly 40-11 wheel bearing 40-11 Fuel filter 03-54, 20-32 Fuel flap lock 57-11, 96-27 Fuel injection see Engine management Fuel injector 24-4, 24-10, Fuel level sender 20-2 Fuel pressure 20-21 relieving system pressure 20-5 residual pressure 20-24 Fuel pump 20-2, 20-4 high pressure 20-31 power supply 20-7 testing 20-4 wiring 20-16 Fuel system components 20-27 diagnostics 20-3 delivery 20-17 evaporative emissions control 20-34 see also Engine management

A408_index.fm Page 4 Wednesday, October 13, 2010 9:38 AM

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INDEX Fuel tank 20-27 capacities 20-1 filler flap lock 57-11, 96-27 filler neck 20-30 Fuses 97-11

Hydraulic fading compensation (HFC) 02-16

I Ignition coil 28-19

G

Ignition shift lock 37-16

Gear selector automatic transmission 37-15 manual transmission 34-9

Ignition switch electrical 96-19 key cylinder 96-18

Generator see Alternator (generator) Glass see Window Glove compartment 70-8 light 96-7 Grill 55-6 Grounds 97-36

H

Ignition system 28-2 coil 28-19 disabling 28-2 firing order 28-2 knock sensor 28-2, 28-7, 28-11 Immobilizer 96-29 Instrument cluster 02-24, 90-1 diagnostics 90-2 removing and installing 90-3 Intake manifold 15-5, 15-12, 24-23 see also Engine management diagrams in 24 Fuel Injection

Hand brake see Parking brake

Intercooler 21-19, 21-20

Headlight 94-3, 94-21 adjusting 03-60 automatic headlight beam adjustment 94-2 suspension level sensor 40-19, 42-9 switch 96-20 washer 92-10 xenon 94-4, 94-9, 94-15, 94-19, 94-21, 94-25, 94-28 see also Lights, exterior

Interior lights see Lights, interior

J Jacking vehicle 03-13

K

Lights, exterior foglights 94-30 switch 96-20 taillights 94-32, 94-35 see also Headlight see also Turn signal Lights, interior 96-2 dome 96-5 Lock carrier, front service position 50-2

M Maintenance accessory belt 03-36 air filter 03-46 ATF 03-58, 37-3 battery 03-33, 27-3 body and interior 03-58 brake fluid 03-29 brake system 03-52 cooling 03-26 CV joint boot 03-52 diagnostic trouble codes (DTCs) access 03-64 dust and pollen filter 03-59 engine covers 03-18 engine oil 03-20 exhaust system 03-53 fuel filter 03-54 headlight adjustment 03-60 parking brake 46-20 schedules 03-66 spark plugs 03-42 timing belt 03-41, 13-2, 13-10, 13-7 tires and wheels 03-54 transmission fluid 03-58 automatic 37-3 manual 34-5 underbody sealant 03-58 under car maintenance 03-58 windshield wipers and washers 03-62 Manual transmission 02-12 gear selector 34-9 identification 03-8 oil 34-5 removing and installing 34-16 specifications 34-2

Heating and ventilation dust and pollen filter 03-59 heater core 87-17 see also Air-conditioning (A/C)

Knock sensor 28-2, 28-7, 28-11

HFC (hydraulic fading compensation) 02-16

L

HID headlight see Xenon headlight

Leak detection 20-34

Master cylinder brakes 47-3 clutch 30-5

High intensity headlight see Xenon headlight

License plate light 94-42

MCB (Multicommunication bar) 91-2

Hood engine hood 55-2

Lid, trunk 55-7

Horn 96-28

Lifting vehicle 03-13

Mirror interior 70-2 outside 66-3 switch 96-23

A408_index.fm Page 5 Wednesday, October 13, 2010 9:38 AM

INDEX WARNING Your common sense, good judgement and general alertness are crucial to safe and successful service work. Before attempting any work on your Audi, be sure to read 00 Warnings and Cautions and the copyright page at the front of the manual. Review these warnings and cautions each time you prepare to work on your car. Please also read any warnings and cautions that accompany the procedures in the manual.

Oxygen sensor see Exhaust system diagrams in 26 Exhaust System see also Fuel injection system components in 24 Fuel Injection– Gasoline

P Parking brake 46-20 P-code OBD-2 Pollen filter 03-59

Motronic see Engine management Muffler see Exhaust system diagrams in 26 Exhaust System Multicommunication bar (MCB) 91-2 Multifunction steering wheel 91-7 Multitronic® transmission (CVT) 02-13 ATF capacity 37-2 level 37-3 identification 03-8

Power steering see Steering Power window see Window

R Radiator 19-8, 19-12, 19-24, 19-34 Radiator grill 55-6 Radio 91-3 removing and installing 91-4 see also Sound systems

S SAC (self-adjusting clutch) 30-21 Safety passenger 02-19 working under car 03-16 Scan tool OBD-2 suppliers OBD-34 Seat belt 69-5 Seats front 72-1 memory 72-6 rear 72-7 side padding 72-15 switch 72-7 Secondary air injection system 26-36 Self-adjusting clutch (SAC) 30-21 Service position lock carrier 50-2 Service reminder indicator 03-65 Shift lock automatic transmission 37-16 Shock absorber 42-4

N

Raising vehicle 03-13

Short circuit 9-5

Navigation 91-5

Rear shelf 70-29

Slave cylinder, clutch 30-12

Rear suspension 02-15 codes 44-2 coil spring 42-3 curb weight position 42-1 overview 42-3 shock absorber 42-4 stabilizer bar 42-5

Sound absorber panels 03-18

Rear window defogger control 87-5

Speaker see Sound system diagrams in 91 Radio and Communication

O OBD II OBD-1 Oil 03-20 capacities 17-1 pan 17-5, 17-8, 17-13, 17-15 pressure switch 17-3 specifications 17-1 see also Engine lubrication

Refrigerant see Air-conditioning (A/C)

Oil filter 03-22

Ribbed belt see Accessory belt

On-board diagnostics OBD-1

Rollover protection AppendixB-17 rpm sensor 28-5, 28-11

Sound system components 91-3 see also Radio Spark plugs 03-42

Special tools suppliers 03-4 Spiral spring 48-4, 96-13 Stabilizer bar front 40-16 rear 42-5

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INDEX Starter 27-20 removing and installing 27-20, 27-21, 27-23, 27-24 Steering angle sensor 45-3, 96-14 column 48-3 column switches ignition 96-19 column trim 48-4, 70-7 fluid 48-1 interlock 48-8 lock 48-8 pump 48-20 rack 48-9 wheel 48-4 Strut front 40-11 Sunroof 60-1 Suspension 02-14 checking 03-53 curb weight position 40-1, 42-1 see also Front suspension see also Rear suspension Switches dashboard 96-21 exterior lights 96-20 ignition and steering lock 96-19 mirror 96-23 steering column switch module 96-12 window 96-24

T Tailgate 55-11 lock 55-16, 57-12 trim 70-32

Tiptronic 02-12

W

Tires 44-1 pressure monitoring system 44-3

Washers 92-10 fluid 03-63 headlight 92-14

Toothed belt see Timing belt Towing 03-11 Transfer case oil 39-5 Transmission identification 03-8 oil 03-58 see also Automatic transmission see also Manual transmission Trim dashboard end 70-3 door 70-17 driver storage compartment 70-9 pillar and side trim 70-23 steering column trim 70-7 tailgate trim 70-32 trunk trim 70-30, 70-36 Trunk lid 55-7 light 96-10 lock 55-11, 57-11 trim 70-30, 70-36 Turbocharger 21-3, 21-10 hoses 21-2, 21-5, 21-11 Turn signal front 94-15, 94-26 switch 96-16

Water pump removing and installing 19-7, 19-11, 19-23, 19-32 Wheel alignment 44-5 Wheel bearing 40-11 Wheel housing liner 66-1 Wheel speed sensor 45-11 Wheels 03-54, 44-1 alignment 44-5 Window glass service 64-2 motor reinitializing 64-1 motor service 64-6 switch 96-24 Wipers arms and blades 92-2 blades 03-62 repairs 92-2, 92-6, 92-9 Wiring diagrams EWD-8 symbols EWD-7 Working under vehicle safely 03-16

V

X

Taillight 94-32, 94-35

Vacuum pressure sensor 47-8

Telematics 91-7

Vacuum pump brake booster 15-17, 47-7

Xenon headlight 94-4, 94-9, 94-15, 94-19, 94-21, 94-25, 94-28 see also Headlight

Telephone 91-5

Vehicle identification number (VIN) 01-1, 03-5

Thermostat 19-4, 19-16, 19-28, 19-38

Vehicle level sensor 40-19, 42-9

Throttle control 20-37

Ventilation dust and pollen filter 03-59 see also Air conditioning (A/C) see also Heating and ventilation

Tie-rod 48-18 Timing belt 03-41, 13-2, 13-10, 13-17 Timing chain (camshaft drive chain) 02-11

Vibration damper 13-4, 13-6, 13-19 Voltage 9-4

established 1950 Automotive Reference™

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