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Service. 6
Maintenance
Audi 100 1991 >
Booklet No. 54: Audi 100 1991>
Edition 01.98
Booklet
Service Department. Technical Information
Service. 6
Maintenance
Audi 100 1991 >
Booklet No. 54: Audi 100 1991>
Edition 01.98
Booklet
Technical Bulletins
Oil Change Service
Inspection Service
Lifting the vehicle
Tow-starting/towing
Technical Information should always be available to all foremen and mechanics, because their com- pliance with
the instructions given is essential to ensure vehicle roadworthiness and safety. In the normal safety precautions
to be observed when working on motor vehicles are also applicable.
All rights reserved.
No reproduction without prior agreement from publisher. Printed in Germany
Copyright © 1998 Audi AG, Ingolstadt 005.5251.50.20
Contents
Page
- Survey of engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Oil Change Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Inspection Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
- Windscreen wiper and washer system and headlight washer system: adjust washer jet settings and check
function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
- Windscreen washer system: check washer jet settings and adjust if necessary . . . . . . . . . . . . . . . . . . . . . . . 15
- Headlight washer system: check washer jet settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
- Wiper blades: check park position and check for damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
- Self-diagnosis: interrogate fault memory with fault reader V.A.G 1551 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
- Service interval display: reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
- Door arresters and lock cylinders: lubricate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
- Sun roof: check function, clean guide rails and spray with lubricating spray . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
- Removing plenum chamber cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
- Battery: check electrolyte level and top up with distilled water if necessary . . . . . . . . . . . . . . . . . . . . . . . . . . 32
- Removing engine cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
- Engine (from above and below) and engine compartment: visual check for leaks and damage . . . . . . . . . . . . 38
- Windscreen / headlight washer system: top up fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
- Cooling system: check antifreeze and top up coolant if necessary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
- Coolant G11: Change (V8 petrol engines only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
- Air cleaner: clean housing and replace filter element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
- Spark plugs: replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
- Hydraulic system: check for leaks, check fluid level and top up hydraulic fluid if necessary . . . . . . . . . . . . . . . 54
- Fuel filter: replace (diesel and TDI engines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
- Fuel filter: drain off water (Diesel and TDI engines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
- Dust and pollen filter: replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
- Plenum chamber and water drain valves: check for dirt and clean if necessary . . . . . . . . . . . . . . . . . . . . . . . . 63
- Noise insulation: remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
- V-belt: check for damage and check tension; adjust tension if necessary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
- V-belts: tensioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
- V-belt (not ribbed belt) for alternator: replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
- Ribbed belt: check for damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
- Ribbed belt: check tension; adjust if necessary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
- V-belt and ribbed belt: replace (4-cyl. 5V engines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
- Ribbed belt: replace (V6 engines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
- Toothed belt for camshaft drive: check for damage and measure toothed belt width (4-cyl. TDI engines) . . . . 81
- Toothed belt for camshaft drive: check for damage and check tension (5-cylinder diesel and TDI engines) . . . 82
- Toothed belt for injection pump: check for damage and check tension (5-cyl. TDI engines), tension toothed belt85
- Toothed belt for camshaft drive: check for damage (2.6l 2V and 2.8l 2V engines only) . . . . . . . . . . . . . . . . . . 89
- Toothed belt: replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
- Manual gearbox/final drive: check oil level and top up if necessary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
- Final drive (automatic gearbox): check oil level and top up if necessary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
- Engine oil: drain or extract, change oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
- Brake system: visual check for leaks and damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
- Brake pads: check thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
- Underseal: visual check for damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
- Track rod ends: check play, attachment and protective boots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
- Tyres: check and correct condition, wear pattern, tread depth and inflation pressures . . . . . . . . . . . . . . . . . . 113
- Wheel bolts: tighten to specified torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
- Engine oil: fill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
- Engine: check oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
- Automatic gearbox: change ATF (except 01N gearbox) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
- Idling speed: check and adjust if necessary (2.4 ltr diesel AAS only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
- Brake fluid level (depending on brake pad wear): checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
- Brake fluid: change brake fluid (every 24 months) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
- Headlights: check settings and adjust if necessary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
- Test drive: perform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
- Vehicle data sticker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
- Engine code and engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
Lifting the vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
Tow-starting/towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
- Arbeitsabläufe Benzinmotoren . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
- Arbeitsabläufe Dieselmotoren . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
- Abgasuntersuchung Deutschland . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
- Arbeitsabläufe Benzinmotoren . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
- Störgröße vorbereiten . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
- Prüfgeräte . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
- Prüfablauf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
- Prüfung mit Fehlerspeicher-Abfrage (V.A.G 1551) zur Lambda-Regelkreisprüfung . . . . . . . . . . . . . . . . . . . . . . 189
- Prüfung ohne Fehlerspeicher-Abfrage (V.A.G 1551) zur Lambda-Regelkreisprüfung . . . . . . . . . . . . . . . . . . . . 190
- Arbeitsablauf Dieselmotoren . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
- Prüfgeräte . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
- Prüfablauf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
Survey of engines
1 The order in which the individual operations are given has been tested and represents the optimum work-
ing sequence. The sequence should therefore be followed to avoid unnecessary work interruptions.
1 The sequence of operations given is based on that specified for the Inspection Service, which is the type
of service most frequently required.
1 Always inform the customer if faults or defects which need repairing are identified during the Inspection
Service.
Code ADA ABB ADR AAE ADW AAD ABK
No of cylinders 4 4 4 4 4 4 4
Valves per cylinder 2 2 5 2 2 2 2
Capacity l 1.6 1.6 1.8 2.0 2.0 2.0 2.0
Output kW at rpm 74
6000
75
6100
92
5800
74
5500
79
5300
85
5400
85
5400
Torque Nm at
rpm
130
3200
127
3700
173
3950
157
2750
160
3200
168
3200
166
3200
Bore øin mm 81.0 81.0 81.0 82.4 82.5 82.5 82.5
Stroke mm 77.4 77.4 86.4 92.8 92.8 92.8 92.8
Compression 10.5 10.0 10.3 9.3 9.0 10.3 10.5
1
Code ADA ABB ADR AAE ADW AAD ABK
Injection/
Ignition
Multi Point
Injection
K-Jetronic/
TSZ-h
Motronic Mono-
Motronic
Digifant KE-
Motronic
Digifant
RON at least 95
(unleaded)
2)
98
(unleaded or
leaded) 3)
95 1)
(unleaded)
91
(unleaded)
88
(unleaded or
leaded)
95 1)
(unleaded)
2)
95 1)
(unleaded)
2)
Hydraulic valve lifters
X X X X X X X
Self-diagnosis X - X X X X X
Catalytic converter X / - 4) - X X - X / - 4) X / - 4)
Lambda control X - X X X X X
Exhaust emission test
after
3, 5, 7, 9 ... years X X X X X X X
1) Regular unleaded petrol RON 91 can be used but will cause a slight loss of power.
2) Unleaded for vehicles with catalytic converter; unleaded or leaded for vehicles without catalytic converter.
3) When using Premium unleaded petrol 95 RON adjust ignition timing to 3 ± 1° before TDC.
4) Optional in some countries.
2
Code ACE AAN AAR AFM ACZ ABC AEJ
No of cylinders 4 5 5 6 6 6 6
Valves per cylinder 4 4 2 2 2 2 2
Capacity l 2.0 2.226 2.3 2.4 2.6 2.6 2.8
Output kW at rpm 103
5900
169
5900
98
5500
110
5800
102
5750
110
5750
120
5400
Torque Nm at
rpm
185
4500
350
1950...3000
186
4000
210
3300
210
3500
225
3500
235
3000
Bore øin mm 82.5 81.0 82.5 81.0 82.5 82.5 82.5
Stroke mm 92.8 86.4 86.4 77.4 81.0 81.0 86.4
Compression 10.8 9.3 10.0 10.0 9.0 10.0 9.2
Injection/
Ignition
KE-
Motronic
Motronic KE III-
Jetronic/
VEZ
Multi Point
Fuel
Injection
Multi Point
Fuel
Injection
Multi Point
Fuel
Injection
Multi Point
Injection
RON at least 95 1)
(unleaded)
95 or 98
(unleaded)
95 1)
(unleaded)
95
(unleaded)
88
(unleaded or
leaded)
95 1)
(unleaded)
88
(unleaded or
leaded)
1) Regular unleaded petrol RON 91 can be used but will cause a slight loss of power.
3
Code ACE AAN AAR AFM ACZ ABC AEJ
CN at least - - - - - - -
Hydraulic valve lifters
X X X X X X X
Self-diagnosis X X X X X X X
Catalytic converter X
X X X - X -
Lambda control X X X X X X X
Exhaust gas recircula-
tion system
- - - - - - -
Turbo
charging - X - - - - -
Exhaust emission test
after
3, 5, 7, 9 ... years X X X X X X X
4
Code AAH ACK ABH AEC AHK 1Z AHU
No of cylinders 6 6 8 8 8 4 4
Valves per cylinder 2 5 4 4 4 2 2
Capacity l 2.8 2.8 4.2 4.2 4.2 1.9 1.9
Output kW at rpm 128
5500
142
6000
206
5800
213
5800
240
6500
66
4000
66
4000
Torque Nm at
rpm
250 5)
3000
280
3200
400
4000
400
4000
400
3500
202
1900 7)
202
1900
Bore øin mm 82.5 82.5 84.5 84.5 84.5 79.5 79.5
Stroke mm 86.4 86.4 93.0 93.0 93.0 95.5 95.5
Compression 10.3 10.6 10.6 10.8 11.6 19.5 19.5
Injection/
Ignition
Multi Point
Injection
Motronic Motronic Motronic Motronic Diesel
(direct injec-
tion)
Diesel
(direct injec-
tion)
RON at least 98 5)
(unleaded)
95 1)
(unleaded)
98 6)
(unleaded)
98 6)
(unleaded)
98 6)
(unleaded)
- -
1) Regular unleaded petrol RON 91 can be used but will cause a slight loss of power.
5) If premium unleaded petrol 95 RON is used, there will be a reduction in torque (245 Nm at 3000 rpm).
6) Premium unleaded petrol RON 95 can be used but will cause a slight loss of power.
7) Vehicles with an airflow meter: 182 Nm at 2300 ... approx. 2500 rpm
5
Code AAH ACK ABH AEC AHK 1Z AHU
CN at least - - - - - 45 45
Hydraulic valve lifters
X X X X X X X
Self-diagnosis X X X X X X X
Catalytic converter
X X X X X
Oxidising
catalytic
converter
Oxidising
catalytic
converter
Lambda control X X X X X - -
Exhaust gas recircula-
tion system
- - - - - X X
Turbo
charging - - - - - X X
Exhaust emission test
after
3, 5, 7, 9 ... years X X X X X X X
6
Code AAS AAT ABP AEL
No of cylinders 5 5 5 5
Valves per cylinder 2 2 2 2
Capacity l 2.4 2.5 2.5 2.5
Output kW at rpm 60
4400
85
4000
85
4000
103
4000
Torque Nm at rpm 164
2400...2500
265
2250
265
2250
290
1900
Bore øin mm 79.5 81.0 81.0 81.0
Stroke mm 95.5 95.5 95.5 95.5
Compression 23.0 20.5 20.5 20.5
Injection/
Ignition
Diesel
(swirl chamber)
Diesel
(direct injection)
Diesel
(direct injection)
Diesel
(direct injection)
RON at least - - - -
7
Code AAS AAT ABP AEL
CN at least 45 45 45 45
Hydraulic valve lifters
X X X X
Self-diagnosis - X X X
Catalytic converter
-
Oxidising catalytic
converter -
Oxidising catalytic
converter
Lambda control - - - -
Exhaust gas recirculation system - X X X
Turbo
charging - X X X
Exhaust emission test after
3, 5, 7, 9 ... years
X X X X
8
Oil Change Service
Work to be completed after
every 7,500 km
only for vehicles with diesel engines (engine code AAS) Page
OIL 1) Work to be completed after
every 15,000 km
only for vehicles completing over 15,000 km a year
Plenum chamber and water drain valves: Check for dirt and clean if necessary 63
Fuel filter: Drain water (diesel and TDI engines only) 58
Toothed belt for camshaft drive: check for damage and measure toothed belt width (4-cyl. TDI engines
only) 81
Engine oil: drain or extract, change oil filter 104
Brake pads: check thickness of disc brake pads 108
Engine oil: fill 118
Service interval display: reset (Audi A6 / S6 only) 24
Audi service sticker: enter date for next service (and for brake fluid change) on sticker and affix on left of
dash panel or on door post (B-pillar)
1) Inspection due according to service interval display (Audi A6 / S6 only)
9
Inspection Service
Inspec-
tion 1)
Interval Work to be completed Page
In 1 Every 12 months Jobs without -/-- positions
In 1 Every 30,000 km Jobs required every 12 months including -positions
In 1 One-off inspection after
60,000 km
Toothed belt for camshaft drive: replace
(5-cyl. TDI engines > 1994 only)
In 1 Every 60,000 km Jobs required every 12 months including -/--positions
In 1 Every 90,000 km In addition to Inspection Service:
Ribbed belt: replace (V6 engines >1994 only)
Toothed belt for camshaft drive and tensioning roller: replace (4-cyl.
TDI engines only)
91
In 1 Every 120,000 km In addition to Inspection Service:
V-belt and ribbed belt: replace (4-cylinder 5V engines)
Ribbed belt: replace (V6 engines >1995 only)
Toothed belt: replace (4 and 5-cyl. petrol engines)
Toothed belt for camshaft and injection pump: replace
(5-cyl. diesel engines)
Toothed belt for camshaft and injection pump: replace
(5-cyl. TDI engines)
Toothed belt and tensioning roller: Replace (V6 5-valve engines only)
Toothed belt and ribbed belt: Replace (V8 engines only)
91
10
Inspec-
tion 1)
Interval Work to be completed Page
In 2 Every 24 months In addition to Inspection Service:
Brake fluid: change 146
In 1 Every 36 months In addition to Inspection Service:
Coolant G11: Renew (V8 petrol engines only)
Coolant "G12" need not be changed, even after changing from "G11"
to "G12" coolant
44
After the first 36
months, then every 24
months
Exhaust emissions test 169
Work to be completed 5
1) Inspection due according to service interval display (Audi A6 / S6 only)
Work to be completed Page
Front and rear lights, turn signals, hazard warning lights, luggage compartment lights: check func-
tion
Interior lights and glove compartment light, warning lamps, horn: check function
Windscreen wiper and washer system and headlight washer system: adjust washer jet settings
and check function
15
Wiper blades: check park position and check for damage 18
Self-diagnosis: interrogate fault memory with fault reader V.A.G 1551 21
Service interval display: reset (Audi A6 / S6 only) 24
Door arresters and lock cylinders: lubricate 30
- Sun roof: check function, clean guide rails and spray with lubricating spray 31
Battery: check electrolyte level and top up with distilled water if necessary 32
11
Engine (from above) and engine compartment: visual check for leaks and damage 38
Windscreen / headlight washer system: top up fluid 39
Cooling system: check antifreeze and top up coolant if necessary 40
-- Air cleaner: clean housing and replace filter element
(every 60,000 km or every 2 years, whichever comes first) 45
- Spark plugs: Replace (vehicles > 1993) 47
-- Spark plugs: Replace (vehicles 1994 >, every 60,000 km or every 3 years, whichever comes first) 47
Continued 5
- Hydraulic system: check for leaks and check fluid level, top up hydraulic fluid if necessary (vehicles >
1991 only)
54
-- Hydraulic system: check for leaks and check fluid level, top up hydraulic fluid if necessary (vehicles >
1992 only)
54
- Fuel filter: Replace (diesel and TDI engines only) 56
Fuel filter: Drain water (diesel and TDI engines only) 58
- Dust and pollen filter: replace
(Audi 100 > 1992 with 2V1 => vehicle data sticker, Audi 100 1993 > 1994 without air conditioner,
Audi A6 1995 >) 61
Plenum chamber and water drain valves: Check for dirt and clean if necessary 63
V-belt: check for damage and check tension; adjust tension if necessary 65
-- V-belt (not ribbed belt) for alternator: Replace (vehicles > 1993 only) 70
- Ribbed belt: check for damage (vehicles > 1994 only) 72
- Ribbed belt: check tension; adjust if necessary
(4-and 5-cyl. 1993 engines only) 73
Toothed belt for camshaft drive: check for damage, measure toothed belt width
(4-cyl. TDI engines only) 81
12
- Toothed belt for camshaft drive: check for damage and check tension
(5-cyl. diesel and TDI engines only) 82
- Toothed belt for injection pump: check for damage and check tension (5-cyl. TDI engines),
adjust tension of toothed belt - Additional job 85
Continued 5
-- Toothed belt for camshaft drive: check for damage (2.6l 2V and 2.8l 2V engines only). 89
Engine (from below): visual check for leaks and damage 38
Gearbox, final drive, steering and protective boots: visual check for leaks and damage
- Manual gearbox/final drive: check oil level and top up if necessary 93
-- Final drive (automatic gearbox): check oil level and top up if necessary 100
Engine oil: drain or extract, change oil filter 104
Brake system (from below): visual check for leaks and damage 107
Brake pads: check thickness 108
- Underseal: visual check for damage 112
Exhaust system: visual check for leaks and damage, check that parts are properly secured
Track rod ends: check play, attachment and protective boots 112
Ball joints: check protective boots for leaks and damage
Tyres (incl. spare wheel): check condition and wear pattern 113
Tyres (incl. spare wheel): check and record tread
depths
FL FR RR RL Spare 114
Tyres (incl. spare wheel): Inflating to correct pressures 114
Engine oil: fill 118
-- Automatic gearbox: change - ATF (additional job) (every 60,000 km or every 4 years, whichever
comes first)
123
13
Idling speed: check and adjust if necessary (2.4 ltr diesel AAS only) 142
Continued 5
Brake fluid level (depending on brake pad wear): check 144
- Headlights: check settings and adjust if necessary 150
Audi service sticker: enter date for next service (and for brake fluid change) on sticker and affix on
left of dash panel or on door post (B-pillar)
Test drive: perform 154
14
Windscreen wiper and washer system
and headlight washer system: adjust
washer jet settings and check function
Note:
If the wiper blades judder or make a noise when
tested, check the contact angle of the wiper blades
=>Page 19.
Windscreen washer system: check
washer jet settings and adjust if neces-
sary
Special tools required
♦ Windscreen wiper jet adjusting tool 3125 A with
needle 3125/5
Note:
Never use pins or other sharp objects as these will
damage the water channels in the jet.
Windscreen washer jet settings
- Mark the four points on the windscreen with wa-
ter-soluble ink.
15
Setting dimensions:
♦ Dimension a = 230 mm
♦ Dimension b = 280 mm
♦ Dimension c = 160 mm
♦ Dimension d = 480 mm
Note:
The setting dimensions are calculated from the outer
edges of the windscreen.
- Use the special tool 3125 A to aim the individual
jets at the points marked.
Notes:
♦ The setting dimensions give the values for the
vehicle when moving. The spray from the jets
will be slightly offset when stationary.
♦ If the jet of water is irregular or cannot be adjus-
ted to the specified setting, replace the jet (re-
pair measure).
16
Rear window washer jet setting
- Adjust the washer jet using special tool 3125 A
so that the water jet is directed onto the rear win-
dow within the dimension a = 280 mm above the
wiper arm pivot mounting.
17
Headlight washer system: check washer
jet settings
The headlight washer jets are set by the manufac-
turer and therefore do not require adjustment.
Wiper blades: check park position and
check for damage
Park position for windscreen wiper blades
- Switch windscreen wipers on and off and allow
to return to the park position.
- Check that the wiper blades are in the correct po-
sition on the windscreen.
- A - End of wiper blade on passenger's side at
upper edge of dotted pattern.
- B - Wiper blade on driver's side: a = 10 mm
below upper edge of dotted pattern.
Note:
The positioning is symmetrically opposite for right -
hand drive vehicles.
- If necessary, loosen the wiper arm, align and
tighten fastening nut.
- Actuate flick wipe switch and check settings.
Tightening torque Nm
Wiper arms to pivot mountings 16
Park position for rear window wiper blade
18
- Switch rear window wipers on and off and allow
to return to the park position.
- Check that the wiper blade is on upper edge of
the dotted pattern on rear window.
- If necessary, loosen the wiper arm, align and
tighten fastening nut.
Tightening torque Nm
Wiper arm to pivot mounting 16
Contact angle of front wiper blades
Note:
Only check the contact angle when the wiper blades
judder or make noises.
Special tools required
♦ Wiper arm adjusting tool 3358
- Switch windscreen wipers on and off and allow
to return to the park position.
- Remove wiper blade.
19
- Insert wiper arm -2- in wiper arm adjusting tool
3358 and secure with locking screw -3-.
- Compare angle indicated to specified value in
table.
Contact angle (specifications)
Driver's side - 4°
Passenger's side - 2°
Tolerance ±0°
- If necessary, adjust the contact angle to the spe-
cified value as follows:
- Place open ended spanner -1- (24 mm A/F) over
adjusting tool and adjust angle of wiper arm -2-
(arrows) according to specified values.
- Release wiper arm -2- from adjusting tool and re-
secure with locking bolt -3-.
- Check set value against table. If necessary, re-
peat setting and checking procedure until spe-ci-
fied value is achieved.
- Remove adjusting tool and fit wiper blade.
- Check that windscreen wiper system operates
without juddering.
20
Self-diagnosis: interrogate fault memory
with fault reader V.A.G 1551
Connecting V.A.G 1551:
- Apply the handbrake.
- Move selector lever to position "P" or "N" on mod-
els with automatic gearbox.
- Remove cover from additional relay carrier I on
left of plenum chamber.
- Ensure that ignition is switched off, then connect
black connector to black diagnostic connection.
V.A.G Indicated on display:
1) appears alternately
Note:
If the display remains blank:
=> Fault Reader Operating Instructions
- Connect white connector to white or brown dia-
gnostic connection (blue connector not required).
21
- Switch on printer with PRINT key (indicator lamp
in key illuminates).
- Enter "1" to select "Rapid data transfer".
Interrogating fault memory
- Start engine and run at idling speed.
- Briefly press brake pedal.
- Enter "00" for address word "Automatic test se-
quence" and confirm entry with Q key. The V.A.G
1551 transmits all known address words in se-
quence.
If a control unit answers with its identification, the
number of faults stored or "No fault detected" ap-
pears on the display.
Any system faults stored will be displayed in se-
quence and printed out. The V.A.G 1551 will then
transmit the next address word.
V.A.G The automatic test sequence has ended when the
following appears on the display:
1) appears alternately
- Switch ignition off.
If faults have been stored, they must be rectified.
The fault print-out is required for carrying out the re-
pair work.
Notes:
♦ It may be necessary to leave V.A.G 1551 con-
nected in order to carry out the exhaust emis-
sion test.
22
♦ On vehicles with 5-cyl. 2V engine (engine code
"AAR") it is also necessary to interrogate the
fault memory for engine electronics in "Flash
code output" mode.
Interrogating fault memory for engine electronics
(engine code "AAR")
- Start engine and run at idling speed.
- Press key "2" for "Flash code output".
- Press ⇒ key.
Any faults (flash codes) stored in the fully-electronic
ignition control unit will appear in sequence on the
display and on the print-out.
Flash code: 4444
No fault detected
If no faults have been stored in the memory, this
message will appear on the display:
Flash code: 0000
Output ends
After the last fault or "Flash code 4444 No faults re-
cognised" has been displayed, this message will ap-
pear on the display:
Notes:
♦ With the printer switched on, V.A.G 1551 will
now advance to the next step and interrogate
the fault memory of the KE III Jetronic control
unit.
♦ The idling speed will be increased while the fault
memory of the KE III Jetronic control unit is in-
terrogated.
Any faults (flash codes) stored in the KE III Jetronic
control unit will appear in sequence on the display
and on the print-out.
23
Flash code: 4444
No fault detected
If no faults have been stored in the memory, this
message will appear on the display:
Flash code: 0000
Output ends
After the last fault or "Flash code 4444 No faults re-
cognised" has been displayed, this message will ap-
pear on the display:
- Switch ignition off.
If faults have been stored, they must be rectified.
The fault print-out is required for carrying out the re-
pair work.
Service interval display: reset
Audi A6 / S6
The service interval display must be reset (using
fault reader V.A.G 1551) after each Oil Change Ser-
vice or Inspection Service.
When a service is due, the type of service required
will be indicated by a flashing message on the trip
recorder display when the ignition is switched on.
The message will continue to flash for up to 60
seconds after the engine has been started.
Display Type of service due
OIL Oil Change Service
In 1 Inspection Service
In 2 Inspection Service with additional jobs
The service due will be indicated either 1,000 km or
10 days in advance.
24
- Connect V.A.G 1551 => Page 23.
- Switch the ignition on.
V.A.G Indicated on display:
1) appears alternately
- Enter "1" to select "Rapid data transfer".
Rapid data transfer HELP
Enter address word XX
Indicated on display
- Enter "17" for address word "Dash panel insert"
and confirm entry with Q key.
4A1919033HG
C4-INSTRUMENT CLUSTER D20 ⇒
Coding 00040 WSC 12345
If following display appears (example):
- Press ⇒ key to continue.
- Enter "10" to select the "Adaption" function and
confirm with the Q key.
Adaption Q
Enter channel no. XX
Indicated on display
- Enter the required adaption channel according to
the following table.
25
Type of
service
due
service
due
to be
can-
celled
Adap-
tion
channel
Input value
OIL OIL 05 00015
In 1 OIL
In 1 (dis-
tance)
In 1
(time)
05
06
07
00015
00030
00036
In 2 OIL
In 1 (dis-
tance)
In 1
(time)
In 2
05
06
07
08
00015
00030
00036
00073
Resetting SID in adaption channel 05 (OIL):
- Enter "05" to select "Adaption channel 05" and
confirm entry with Q key.
Channel 5 Adaption 1 ⇒
(-1 3-L
Indicated on display:
The figure displayed indicates the number of kilo-
metres remaining until the OIL Service is due (e.g.
"1" for 1,000 km).
- Press ⇒ key.
Channel 5 Adaption 1 Q
Enter adaption value XXXXX
Indicated on display
- Enter "00015" for "15,000 km until next OIL Ser-
vice" and confirm with Q key.
26
Note:
Always enter the distance in kilometres even for
vehicles that are calibrated for miles.
Channel 5 Adaption 15 Q
(-1 3-L
Indicated on display
- Confirm entry with Q key.
Channel 5 Adaption 15 Q
Store changed value?
Indicated on display
- Confirm entry with Q key.
Channel 5 Adaption 15 ⇒
Changed value is stored
Indicated on display
- By pressing the ⇒ key complete resetting pro-
cedure for SID in "adaption channel 05".
Resetting SID in adaption channel 06 (In 1):
- Enter "06" to select "Adaption channel 06" and
confirm entry with Q key.
Channel 6 Adaption 1 ⇒
(-1 3-L
Indicated on display:
The figure displayed indicates the number of kilo-
metres remaining until the next Inspection Service 1
is due (e.g. 1 for 1,000 km).
- Press ⇒ key.
Channel 6 Adaption 1 Q
Enter adaption value XXXXX
Indicated on display
- Enter "00030" for "30,000 km until next Inspection
Service 1" and confirm with Q key.
Note:
Always enter the distance in kilometres even for
vehicles that are calibrated for miles.
27
Channel 6 Adaption 30 Q
(-1 3-L
Indicated on display
- Confirm entry with Q key.
Channel 6 Adaption 30 Q
Store changed value?
Indicated on display
- Confirm entry with Q key.
Channel 6 Adaption 30 ⇒
Changed value is stored
Indicated on display
- By pressing the ⇒ key complete resetting pro-
cedure for SID in "adaption channel 06".
Resetting SID in adaption channel 07 (In 1):
- Enter "07" to select "Adaption channel 07" and
confirm entry with Q key.
Channel 7 Adaption 1 ⇒
(-1 3-L
Indicated on display:
The display will show the number of days remaining
before Inspection Service 1 is due. In this example, 1 =
10 days).
- Press ⇒ key.
Channel 7 Adaption 1 Q
Enter adaption value XXXXX
Indicated on display
- Enter "0036" for "365 days until next Inspection
Service 1" and confirm with Q key.
Channel 7 Adaption 36 Q
(-1 3-L
Indicated on display
- Confirm entry with Q key.
Channel 7 Adaption 36 Q
Store changed value?
Indicated on display
- Confirm entry with Q key.
Channel 7 Adaption 36 ⇒
Changed value is stored
Indicated on display
28
- By pressing the ⇒ key complete resetting pro-
cedure for SID in "adaption channel 07".
Resetting SID in adaption channel 08 (In 2):
- Enter "08" to select "Adaption channel 08" and
confirm entry with Q key.
Channel 8 Adaption 12 ⇒
(-1 3-L
Indicated on display:
The display will show the number of days remaining
before Inspection Service 2 is due. In this example,
12 = 120 days).
- Press ⇒ key.
Channel 8 Adaption 12 Q
Enter adaption value XXXXX
Indicated on display
- Enter "00073" for "730 days until next Inspection
Service 2" and confirm with Q key.
Channel 8 Adaption 73 Q
(-1 3-L
Indicated on display
- Confirm entry with Q key.
Channel 8 Adaption 73 Q
Store changed value?
Indicated on display
- Confirm entry with Q key.
Channel 8 Adaption 73 ⇒
Changed value is stored
Indicated on display
- By pressing the ⇒ key complete resetting pro-
cedure for SID in "adaption channel 08".
29
Door arresters and lock cylinders: lubric-
ate
- Only grease the door arresters at the points
shown in the illustration -arrows-.
- Lubricant: "G 052 778 A2"
- Lubricate the lock cylinder.
- Lubricant: "G 052 778 A2"
30
Sun roof: check function, clean guide
rails and spray with lubricating spray
- Check the sun roof for leaks.
- Clean the guide rails.
- Spray the guide rails.
- Lubricant: "G 052 778 A2"
- Check function of sun roof.
Removing plenum chamber cover
- Pull plenum chamber cover - 1 - out of retaining
clips -arrows- and lift up at the front.
- Detach plenum chamber cover to front.
Note:
When installing the plenum chamber cover, insert it
carefully under the water deflector on the bottom
edge of the windscreen to prevent water from enter-
ing the dust and pollen filter or the heating system.
31
Battery: check electrolyte level and top
up with distilled water if necessary
Fitting location of battery:
♦ Vehicles without jump lead connection in engine
compartment:
below plenum chamber cover on right
♦ Vehicles with jump lead connection in engine
compartment:
below rear seat bench on right
♦ Vehicles with auxiliary heater:
additional (2nd) battery on left of luggage com-
partment behind cover in side trim
Vehicles without jump lead connection in engine
compartment:
- Remove plenum chamber cover => Page 31.
32
Vehicles with jump lead connection in engine
compartment:
- To remove rear seat bench, unscrew cross-head
screws on left and right.
- Raise rear seat bench slightly and take out to-
wards the front.
Additional (2nd) battery on vehicles with auxili-
ary heater:
- Open cover in side trim on left of luggage com-
partment.
All models:
- Checking electrolyte level:
- The electrolyte level should be between the
MIN and MAX markings.
- If necessary, top up battery cells to max. mark
with distilled water.
Notes:
♦ For batteries with clearly visible min and max
mark, the electrolyte level can be checked visu-
ally from the outside of the battery.
♦ If the electrolyte level is not visible from the out-
side unscrew the battery caps.
♦ The electrolyte level must align with the marking
inside the battery - plastic web - . This corres-
ponds to the outer max marking.
33
Removing engine cover
- Loosen bolts and nuts -arrows- and take off en-
gine cover.
4-cyl. 5V engines
V6 - 2V-engines:
34
V6 - 5V engines:
V8-engines > 1994:
35
V8-engines 1995 > :
4-cyl. TDI engines
36
5-cyl. TDI engines
37
Engine (from above and below) and en-
gine compartment: visual check for
leaks and damage
Perform visual check as follows:
- If necessary, remove engine cover => Page 34.
- Check engine and engine compartment for leaks
and damage.
- Check the pipes, hoses and connections of the
following systems for leaks, chafing, porosity and
brittleness.
- Fuel system
- Cooling and heating system
- Brake system
- Perform a visual check of the same areas from
below with the vehicle raised on a lifting platform
and the noise insulation removed.
Important
Faults found must be rectified (repair meas-
ure).
38
Windscreen / headlight washer system:
top up fluid
- Fill container in engine compartment to the top
with washer fluid.
On Avant models, the container for the rear window
washer is at the back of the luggage compartment,
behind the side trim on the right.
- To fill container, swivel filler pipe on container in-
to luggage compartment -arrow-.
Note:
The washer fluid must always contain a pH-neutral
screen cleaning fluid (antifreeze in winter).
Intensive washer system
The fluid container for the intensive washer system
is on the right of the plenum chamber, next to the
cover.
- Fill container right up to the top with intensive
cleaning fluid "D 005 100 10".
Note:
To avoid damaging the paintwork and causing discol-
ouring, do not use any other intensive cleaning fluid
than "D 005 100 10".
39
Cooling system: check antifreeze and
top up coolant if necessary
Notes:
♦ The cooling system is filled all year round with a
mixture of water and antifreeze/corrosion pro-
tection agent.
♦ Coolant additive "G 011 A8 C" (green) is used up
to vehicle identification no. 4AVN 002 872.
♦ Coolant additive "G 012 A8 D" (red) is used as of
vehicle identification no. 4AVN 002 873.
Important
The two different coolant additives "G 011 A8
C" (green) and "G 012 A8 D" (red) must not be
mixed together. Otherwise, this can result in
serious damage to the engine.
♦ If the fluid in the expansion tank is brown, this
means G 012 A8 D has been mixed with another
type of coolant. In this case, flush out the cool-
ing system and fill with fresh coolant. To flush
the system, fill it with clean water and run the
engine for about 2 minutes. This should remove
as much of the old coolant as possible.
40
♦ "G 011 A8 C" and coolant additives "conforming
to TL VW 774 C" or "G 012 A8 D" and coolant ad-
ditives "conforming to TL VW 774 D" prevent
frost and corrosion damage, scaling and also
raise the boiling point of the coolant. For these
reasons the cooling system must be filled all
year round with the correct anti freeze and anti
corrosion additive.
Checking coolant level and topping up if neces-
sary
- Check coolant level on expansion tank while the
engine is cold.
♦ Coolant level between MIN and MAX marks
- If coolant level is too low, add required amount
according to mixture ratio.
Mixture ratio
Frost protec-
tion to
Coolant additive Water
- 25 °C approx. 40 % 1) approx. 60 %
- 35 °C approx. 50 % approx. 50 %
- 40 °C approx. 60 % approx. 40 %
1) For V8 engines 40 % concentration of coolant
additive is not sufficient to give adequate protection
against corrosion.
Notes:
41
♦ Because of its high boiling point, the coolant im-
proves engine reliability under heavy loads, par-
ticularly in countries with tropical climates.
♦ Protection against frost must be assured to
about - 25 °C (for V8 engines and in countries
with an arctic climate to about -35 °C).
♦ The coolant concentration must not be reduced
by adding water even in warmer seasons and in
warmer countries. The proportion of anti-freeze
must be at least 40 % (50 % for V8 engines).
♦ If greater frost protection is required in very cold
climates, the amount of "G 011 A8 C" or "G 012
A8 D" can be increased, but only up to 60 % (or
54 % for V8 engines). This gives frost protection
to around -40 °C), as otherwise frost protection
is reduced again and cooling effectiveness is
also reduced.
Checking antifreeze and topping up coolant ad-
ditive if necessary
- If the degree of frost protection is too low, drain
off the required quantity as specified in the frost
protection table (=> Page 43) and add coolant ad-
ditive:
- Up to vehicle identification number 4AVN 002
872
"G 011 A8 C" or
coolant additive "according to TL VW 774 C"
- From vehicle identification number 4AVN 002
873
"G 012 A8 D" or
coolant additive "according to TL VW 774 D"
42
Note:
Observe environmental requirements for disposal.
Frost protection table
Frost protec-
tion to °C
Required quantity in litres
Actual
value
Spe-
cified
value
4-/5-
cyl.
petrol
en-
gine
4-/5-
cyl.
diesel
en-
gine
5-cyl.
4V
6-cyl. 8-cyl.
0 -25 3.0 3.5 4.0 5.0 -
-35 3.5 4.0 5.0 6.0 6.0
-5 -25 2.5 3.0 3.5 4.5 -
-35 3.5 3.5 4.5 5.5 5.5
-10 -25 2.0 2.0 3.0 3.5 -
-35 3.0 3.0 4.0 4.5 4.5
-15 -25 1.5 1.5 2.0 2.5 -
-35 2.5 2.0 3.0 3.5 3.5
-20 -25 1.0 1.0 1.5 1.5 -
-35 2.5 1.5 2.0 2.5 2.5
-25 -35 2.0 1.0 1.5 1.5 1.5
-30 -35 1.0 0.5 1.0 1.0 1.0
-35 -40 0.5 0.5 0.5 0.5 0.5
- Check coolant additive concentration after test
drive.
43
Coolant G11: Change (V8 petrol engines
only)
To prevent corrosion damage, the coolant must be
changed at regular intervals in vehicles with V8 pet-
rol engines up to vehicle identification no. 4AVN 002
872 if coolant additive "G 011 A8 C" (green) has been
used.
- Draining and filling cooling system
=> 8-cylinder Engine, Mechanical Components; Re-
pair group 19; Removing and installing parts of the
cooling system; Draining and filling system with
coolant
Notes:
♦ Observe environmental requirements for dispos-
al.
♦ When changing the coolant it is also possible to
use coolant additive "G 012 A8 D" (red) instead
of coolant additive "G 011 A8 C" (green). If
switching to "G 012 A8 D", always follow the rel-
evant instructions:
=> 8-cylinder Engine, Mechanical Components; Re-
pair group 19; Removing and installing parts of the
cooling system; Draining and filling system with
coolant
♦ After switching to coolant additive "G 012 A8 D"
(red) it is no longer necessary to change the
coolant (system is then filled for life).
44
Air cleaner: clean housing and replace
filter element
Engines without mixture control unit on air filter
cover:
- Loosen hose clamp on air intake pipe/hose and
detach pipe/hose.
- Release clips -arrows- around air cleaner housing
and press cover to the side.
- If necessary, unplug connector for air mass
meter/air flow meter.
- Remove old filter element.
Note:
Observe environmental requirements for disposal.
- Clean filter housing and install new filter element.
Note:
On vehicles with V6 - 5V-petrol engines renew the
spark plugs and fit the spark plug connectors before
refitting the top section of the air cleaner.
45
Engines with mixture control unit on air filter
cover:
- Remove air intake hose above mixture control
unit.
- Release clips around air cleaner housing -arrows-.
- Pull out mixture control unit with upper section of
air cleaner housing from above.
- Remove old filter element.
Note:
Observe environmental requirements for disposal.
- Clean filter housing and install new filter element.
Audi S4 (V8):
- Unbolt upper section of air cleaner housing.
- Remove old filter element.
Note:
Observe environmental requirements for disposal.
- Clean filter housing and install new filter element.
46
Spark plugs: replace
Special tools required
♦ Spark plug socket, A/F 20.8
(4-cyl. 2V and 5-cyl. 2V engines)
♦ Spark plug socket 3122 B
(4-cyl. 4V, 4-cyl. 5V, 5-cyl. 4V engines, 6- and 8-
cylinder engines)
Notes:
♦ The spark plugs must be renewed every 15,000
km if the vehicle is run on leaded fuel.
♦ Spark plug designation
=> "Exhaust Emission Test" binder
♦ Observe environmental requirements for dispos-
al.
4-cyl. 2V and 5-cyl. 2V engines:
- With ignition switched off, unplug connectors
from spark plugs.
- Remove spark plugs with spark plug socket.
- Screw in new spark plugs.
- Check ignition cables and spark plug connectors
are correctly seated.
Tightening torque Nm
Spark plugs in cylinder head 30
47
4-cyl. 4V engines:
- With ignition switched off, unplug connectors -ar-
rows- from spark plugs.
Note:
Use the special puller fitted on the spark plug con-
nector of cylinder 1 to detach all the spark plug con-
nectors.
- Remove spark plugs using spark plug socket
3122 B.
- Screw in new spark plugs.
- Check ignition cables and spark plug connectors
are correctly seated.
Tightening torque Nm
Spark plugs in cylinder head 30
4-cyl. 5V engines:
- Remove engine cover => Page 34.
48
- With ignition switched off, unscrew and unclip
connector and earth wire from ignition coil with
output stage -arrows-.
- Remove spark plugs using spark plug socket
3122 B.
- Fit spark plugs and ignition coil with output stage.
- Check ignition cables and spark plug connectors
are correctly seated.
Tightening torques Nm
Spark plugs in cylinder head 30
Ignition coil with output stage to cyl-
inder head cover 10
49
5-cyl. 4V engines (turbo):
- Unscrew mountings of ignition coil carrier -arrows-
and pull carrier evenly off towards the top.
- Remove spark plugs using spark plug socket
3122 B.
- Screw in new spark plugs.
- Install ignition coil carrier; replace gasket if dam-
aged.
Tightening torques Nm
Spark plugs in cylinder head 30
Ignition coil carrier to cylinder head
cover
10
50
V6 - 2V engines:
- If necessary remove air intake pipe -1- between
air cleaner and throttle valve unit.
- Remove engine cover => Page 34.
- With ignition switched off, unplug connectors -ar-
rows- from spark plugs.
- Remove spark plugs using spark plug socket
3122 B.
- Screw in new spark plugs.
- Check ignition cables and spark plug connectors
are correctly seated.
Tightening torque Nm
Spark plugs in cylinder head 30
V6 - 5V engines:
- Remove air intake pipe between air cleaner and
throttle valve unit.
- To unscrew rear left spark plug, remove coolant
expansion tank and connected hoses.
- Remove engine cover => Page 34.
51
- Detach spark plug connector -arrows-.
- Remove spark plugs using spark plug socket
3122 B.
- Screw in new spark plugs.
- Check ignition cables and spark plug connectors
are correctly seated.
Tightening torque Nm
Spark plugs in cylinder head 30
V8 engines (206 and 213 kW):
- Remove air intake pipe between air cleaner and
throttle valve unit.
- Remove engine covers => Page 40.
- With ignition switched off, unplug connectors
from spark plugs.
Note:
Use the special puller -arrow- fitted on the spark plug
connector of cylinder 1 to detach all the spark plug
connectors.
- Remove spark plugs using spark plug socket
3122 B.
- Screw in new spark plugs.
- Check ignition cables and spark plug connectors
are correctly seated.
Tightening torque Nm
Spark plugs in cylinder head 30
V8 engines (240 kW):
52
- Remove air intake pipe between air cleaner and
throttle valve unit.
- Remove engine covers => Page 40.
- With the ignition switched off, pull the retainer
clips for the ignition coil connectors upwards and
unplug the connectors.
- Unscrew ignition coils -arrows-.
- Remove spark plugs using spark plug socket
3122 B.
- Install new spark plugs using spark plug socket.
- Install ignition coils. Replace seals if damaged.
Tightening torques Nm
Spark plugs in cylinder head 30
Ignition coils to cylinder head cover 10
53
Hydraulic system: check for leaks, check
fluid level and top up hydraulic fluid if
necessary
Note:
In the case of vehicles with self-levelling suspension,
the vehicle must be in its unladen state when check-
ing the fluid level.
• Cold fluid:
- Do not run engine and set front wheels to
straight-ahead position.
• Fluid at operating temperature (from approx. 50
°C):
- Run engine and set front wheels to straight -
ahead position.
- Unscrew filler cap -arrow- with dipstick.
- Wipe dipstick with a clean cloth.
- Screw in cap hand-tight and unscrew again.
54
- Check fluid level:
• Cold fluid:
- Level must be around MIN. mark (up to 2 mm
above or below mark).
• Fluid at operating temperature (from approx. 50
°C):
- Level must be between MIN. and MAX. mark.
Notes:
♦ The definitive fluid level is the one measured
after screwing in the cap.
♦ Fluid must be drawn off if the level is above the
specified range.
Important
If the fluid level is below the range specified,
the hydraulic system must be checked for
leaks (repair measure). It is then not sufficient
to merely top up the fluid.
- If there are no leaks in the hydraulic system, top
up with "G 002 000".
- Screw in cap hand-tight.
55
Fuel filter: replace (diesel and TDI en-
gines)
Notes:
♦ Please ensure that no diesel fuel contacts
coolant hoses. If necessary, clean hoses imme-
diately.
♦ Observe environmental requirements for dispos-
al.
4-cyl. TDI engines:
- Loosen hose clamps on fuel hoses -1- and -2- and
disconnect both fuel hoses.
- Loosen nut -arrow- on filter bracket and pull filter
out of bracket without disconnecting the two fuel
hoses.
- Using a 17 mm open-ended spanner, counterhold
upper part of fuel filter at flats on boss for bleed
screw. Unscrew filter using strap wrench if ne-
cessary -arrow-.
Important
Do not use pliers to hold the fuel filter. This
can damage the head of the filter and cause
leaks in the fuel system.
- Unscrew filter from upper part of fuel filter.
- coat new rubber seal lightly with diesel fuel.
- Fill new filter with clean diesel. This will enable
the engine to start more quickly.
56
- Screw filter onto upper part of filter flange (hand-
tight).
- Push plastic insert onto new filter.
- Insert fuel filter into bracket and secure with
clamping nut -arrow-.
- Connect fuel hoses -1- and -2- and secure with
new hose clamps (use correct type - same as ori-
ginal equipment).
=> Parts List
- Start engine and check fuel system for leaks
(visual check).
Tightening torque Nm
Clamping nut on filter bracket 10
5-cyl. diesel and TDI engines:
- Unplug connector for water level sender.
- Hold filter in place using a strap wrench, unscrew
banjo bolt -1- and remove filter.
Note:
Do not turn filter.
- Moisten new seal and new rubber seal with dies-
el.
- Transfer water level sender (if fitted) with new O-
ring onto replacement filter.
- Fill new filter with clean diesel. This will enable
the engine to start more quickly.
- Fit a new O-ring and tighten banjo bolt hand-tight.
57
- Start engine and check fuel system for leaks
(visual check).
- Press the accelerator pedal several times - with
the engine running at idling speed the fuel should
flow through the transparent pipe with no
bubbles.
Fuel filter: drain off water (Diesel and
TDI engines)
Notes:
♦ Please ensure that no diesel fuel contacts
coolant hoses. If necessary, clean hoses imme-
diately.
♦ Observe environmental requirements for dispos-
al.
4-cyl. TDI engines:
- Release hose clamps on fuel hoses -1- and -2-
and disconnect both fuel hoses.
- Loosen nut -arrow- on filter bracket and pull filter
out of bracket without disconnecting the two fuel
hoses.
58
- Open water drain plug and drain approx. 0.1 litre
of fluid into a drip tray.
- Close water drain screw.
- Coat rubber seal on fuel filter lightly with diesel
fuel.
- Insert fuel filter into bracket and secure with
clamping nut -arrow-.
- Connect fuel hoses -1- and -2- and secure with
new hose clamps (use correct type - same as ori-
ginal equipment).
=> Parts List
- Start engine and check fuel system for leaks
(visual check).
Tightening torque Nm
Clamping nut to filter bracket 10
59
5-cyl. diesel and TDI engines:
- Release vent screw -2-.
- Fit hose onto water drain screw or breather valve -
3-.
Note:
Vehicles > 1994 with engine code AAT and ABP
have a water drain valve instead of a water drain
screw.
- Unscrew water drain screw or press drain valve
upwards and drain off about 0.1 litre of fluid.
- Tighten water drain screw or release drain valve
and tighten vent screw.
- Start engine and check fuel system for leaks
(visual check).
- Press the accelerator pedal several times - with
the engine running at idling speed the fuel should
flow through the transparent pipe with no
bubbles.
60
Dust and pollen filter: replace
The filter is located below the plenum chamber cov-
er on the right.
Vehicle Page
Audi 100 > 1992 without air conditioner
with M-Nr. 2V1 61
Audi 100 1993 > 1994 without air condi-
tioner
61
Audi A6 1995 > without air conditioner 61
Audi A6 1995 > with air conditioner 62
Audi 100 > 1994 without air conditioner:
- Remove plenum chamber cover => Page 31.
- Unscrew both nuts -A-.
- Turn filter cartridge and take out of bracket.
Note:
Observe environmental requirements for disposal.
- Install new filter element.
- Before fitting plenum chamber cover, check plen-
um chamber and water drain valves for dirt =>
Page 63.
Audi A6 1995 > without air conditioner:
- Remove plenum chamber cover => Page 31.
- Depending on the size of the battery, either
loosen battery retainer and push battery towards
wing panel or remove battery completely.
61
- Push clamp -A- up and remove dust and pollen fil-
ter -B- from filter holder.
Note:
Observe environmental requirements for disposal.
- Install new filter element.
- Before fitting plenum chamber cover, check plen-
um chamber and water drain valves for dirt =>
Page 63.
Audi A6 1995 > with air conditioner:
- Remove plenum chamber cover => Page 31.
- Unscrew the three bolts -A-.
- Remove cover -B- and pull dust and pollen filter -
C- out of evaporator.
Note:
Observe environmental requirements for disposal.
- Before installing dust and pollen filter, check
evaporator for dirt and clean if necessary.
- Insert dust and pollen filter (ensure that filter is
the right way round).
- Arrow on filter element points towards evaporat-
or.
- Before fitting plenum chamber cover, check plen-
um chamber and water drain valves for dirt =>
Page 63.
62
Plenum chamber and water drain
valves: check for dirt and clean if neces-
sary
- Remove plenum chamber cover => Page 31.
- Check plenum chamber for dirt (leaves, etc.) and
clean as necessary.
- Check that water drain valves are functioning
properly, and clean and replace as necessary.
Note:
Ensure that water drain valves close properly and are
not blocked by wax or underseal.
- Observe note on installing plenum chamber cover
=> Page 31.
63
Noise insulation: remove
On vehicles with diesel and TDI engines the noise in-
sulation consists of two parts.
- Turn quick - release screws - arrows - in an anti -
clockwise direction.
- Pull front noise insulation off bumper towards
rear of vehicle and remove.
- Pull rear noise insulation (on diesel and TDI en-
gines only) towards rear of vehicle and remove.
Note:
When installing ensure that the noise insulation is
pushed in over the bumper cover at the front.
64
V-belt: check for damage and check ten-
sion; adjust tension if necessary
- Check condition of V-belts along entire length of
belt:
- Cracks, fractured core, cross-sectional breaks
- Layer separation (base, cord strands)
- Base break-up
- Fraying of cord strands
- Wear on sides of belt (material worn down,
sides of belt frayed, surface cracking or sides of
belt hardened - indicated by smooth, shiny sur-
face)
- Traces of oil and grease
Important
Faults found must be rectified (repair meas-
ure).
- Check tension of V-belts:
- Press in the ribbed belt firmly with the thumb at a
point half-way between the two pulleys which are
farthest apart.
The amount of yield should be as follows:
65
V-belt for alternator Belt yield (max)
- New V-belt 2 mm
- Used V-belt 5 mm
V-belt for PAS vane pump
- Petrol engines 10 mm
- TDI engines 5 mm
V-belt for air conditioner
compressor
- All models 5 mm
V-belts: tensioning
Note:
With the 4-cyl. 5V-engine it is not possible to adjust
the tension of the V-belt for the coolant pump.
Special tools required
♦ V.A.G 1410 Torque wrench
♦ Ring spanner attachment V.A.G 1410/2 (22 mm
A/F)
• V-belt for alternator
66
- loosen all bolts securing alternator and tensioning
bar -A- at least one turn.
- Loosen clamping bolt for tensioner nut -B-.
- Using torque wrench V.A.G 1410 and ring span-
ner attachment V.A.G 1410/2 (22 mm A/F), apply
the following torque to the tensioner nut:
- Used V-belt:4 Nm
- New V-belt: 8 Nm
- Maintain this torque on tensioning bolt, and tight-
en clamping bolt to 35 Nm.
Tightening torques Nm
Clamping bolt for tensioner nut to ten-
sioning bar
35
Tensioning bar to lifting eye 20
Alternator to bottom mounting 35
Note:
If the V-belt has been replaced:
- Start engine and run at idling speed for 5
minutes.
- Switch off the engine and re-adjust the belt ten-
sion as described above.
- Apply a torque of 8 Nm to tensioner nut.
• V-belt for PAS vane pump
- Remove noise insulation => Page 64.
67
- Loosen bolts 2 ... 6.
- Adjust belt tension with tensioner nut -1-.
- The amount of yield should be as follows:
- Petrol engines:10 mm
- TDI engines: 5 mm
- Tighten securing bolts on vane pump.
Tightening torques Nm
Vane pump to bracket 25
Vane pump to tensioning bar 25
• V-belt for air conditioner compressor
- Remove noise insulation => Page 64.
- Unscrew the 4 nuts -1-.
- Detach hub -2- from belt pulley.
- Take off front section of belt pulley -3-.
Notes:
♦ Belt tension is adjusted by adding or taking out
shims -5- between front section -3- and rear sec-
tion -4- of belt pulley.
♦ To reduce tension, add shims between two sec-
tions of belt pulley.
♦ To increase tension, remove shims between
two sections of belt pulley.
68
- Place remaining shims between hub -2- and the
front section of belt pulley -3-.
- Loosely bolt together the two sections of the belt
pulley.
- Tighten the bolts securing the two sections of the
pulley in stages while turning the crankshaft.
- As the bolts are tightened, the V - belt should
gradually move outwards until seated on the
contact surface.
- Tighten nuts to 25 Nm.
- The amount of yield should be as follows:
- Used V-belt:5 mm
- New V-belt: 2 mm
- Start engine and check belt running.
- Check the belt tension again and re-adjust if ne-
cessary.
69
V-belt (not ribbed belt) for alternator: re-
place
Special tools required
♦ V.A.G 1410 Torque wrench
♦ Ring spanner attachment V.A.G 1410/2 (22 mm
A/F)
4-cyl. petrol engines
- Remove noise insulation => Page 64.
- Remove V-belt for air conditioner compressor:
- Unscrew the 4 nuts -1-.
- Detach hub -2- from belt pulley.
- Take off front section of belt pulley -3-.
- Remove V-belt.
70
- Remove V-belt for PAS vane pump:
- Loosen bolts 2 ... 6.
- Remove V-belt.
- Remove V-belt for alternator:
- loosen all bolts securing alternator and tensioning
bar -A- at least one turn.
- Loosen clamping bolt for tensioner nut -B-.
- Fit new V-belt for alternator.
- Re-install the other V-belts.
- Tension the V-belts => Pages 68.
71
Ribbed belt: check for damage
- Check condition of ribbed belts along entire
length of belt:
- Cracks, fractured core, cross-sectional breaks
- Layer separation (base, cord strands)
- Base break-up
- Fraying of cord strands
- Wear on sides of belt (material worn down,
sides of belt frayed, surface cracking)
- Traces of oil and grease
Important
Faults found must be rectified (repair meas-
ure).
72
Ribbed belt: check tension; adjust if ne-
cessary
Special tools required
♦ V.A.G 1410 Torque wrench
♦ Ring spanner attachment V.A.G 1410/2 (22 mm
A/F)
- Press in the ribbed belt firmly with the thumb at a
point half-way between the pulleys.
- The belt should yield 5 mm
- Loosen the alternator securing bolt -1- and clamp-
ing bolt -2- at least one turn.
- Using torque wrench V.A.G 1410 and ring span-
ner attachment V.A.G 1410/2 (22 mm A/F), apply
a torque of 6 Nm to the tensioner nut -3-:
- Maintain this torque on the tensioning bolt, and
tighten clamping bolt to 25 Nm.
Tightening torques Nm
Clamping bolt for tensioner nut to ten-
sioning bar
25
Alternator to bottom mounting 25
73
V-belt and ribbed belt: replace (4-cyl. 5V
engines)
Special tools required
♦ Mandrel 3204
Removing
• Ribbed belt for air conditioner compressor
- Unbolt torque reaction support from engine and
cross member -arrows-.
- Loosen bolts -arrows- of tensioner for ribbed belt,
slacken belt and remove.
• Ribbed belt for PAS vane pump and alternator
74
- Remove ribbed belt for air conditioner com-
pressor => Page 74.
- Loosen ribbed belt for hydraulic pump and altern-
ator, secure tensioner for ribbed belt using man-
drel 3204 if necessary -arrows-.
- Remove ribbed belt between hydraulic pump and
alternator at alternator.
• V-belt for coolant pump
- Unscrew pulley for coolant pump. To prevent pul-
leys from turning, insert a pin -arrow- in the vane
pump pulley.
- Remove V-belt.
Installing
Installation is carried out in the reverse order; note
the following:
- Fit ribbed belt for PAS vane pump and alternator.
- Fit V-belt and assemble two sections of pulley on
coolant pump without tightening bolts.
- Tighten the bolts securing the two sections of the
pulley in stages while turning the coolant pump.
- As the bolts are tightened, the V - belt should
gradually move outwards until seated on the
contact surface.
- Tighten bolts to 25 Nm.
75
Note:
It is not possible to adjust the tension of the V-belt
for the coolant pump.
- Check that ribbed belt is properly seated.
- Turn ribbed belt tensioner in direction of arrow.
- Remove mandrel 3204 if necessary.
- Fit ribbed belt for A/C compressor.
- Apply torque wrench to hexagon on tensioning
roller and tension with a torque of 25 Nm.
- At the same time, tighten bolts -A- to 20 Nm.
- Start engine and check belt running.
- Check again to ensure that the bolts for the
coolant pump pulley are tightened to the correct
torque.
76
Ribbed belt: replace (V6 engines)
Special tools required
♦ Mandrel 3204
- Remove engine cover => Page 34.
- Remove cover for ribbed belt -arrows-.
77
Vehicles > 1991:
- To slacken ribbed belt, turn tensioner in direction
of arrow using ring spanner (15 mm A/F).
- Secure tensioner by inserting mandrel 3204.
- Remove ribbed belt.
- Fit new ribbed belt onto drive pulley and idler
wheel first, and then push it over the tensioner.
Routing of belt
- A1 - without air conditioner
- A2 - with air conditioner
- Take out mandrel 3204 and release tensioner for
ribbed belt.
- Start engine and check belt running.
78
Vehicles 1992 >:
- To slacken ribbed belt, turn tensioner in direction
of arrow using Allen key (10 mm A/F).
- Insert mandrel 3204 into holes -A- and -B- to stop
tensioner from turning.
- Remove ribbed belt.
- Fit new ribbed belt onto drive pulley and idler
wheel first, and then push it over the tensioner.
Routing of belt on vehicles 1992 > 1994
- B1 - without air conditioner
- B2 - with air conditioner
79
Routing of belt on vehicles 1995 >
- C1 - without air conditioner
- C2 - with air conditioner
- Take out mandrel 3204 and release tensioner for
ribbed belt.
- Start engine and check belt running.
80
Toothed belt for camshaft drive: check
for damage and measure toothed belt
width (4-cyl. TDI engines)
- Release 2 clamps on the upper toothed belt cover
and pull upper end of cover forwards.
- Check condition of toothed belt:
- Cracks, cross-sectional fractures
- Layer separation (base, cord strands)
- Base break-up
- Fraying of cord strands
- Surface cracks (plastic outer layer)
- Traces of oil and grease
Important
Faults found must be rectified (repair meas-
ure).
- Measure width of toothed belt -a-.
- Wear limit = 22 mm
Important
The toothed belt must be replaced if the belt
width is less than 22 mm (repair measure).
81
Toothed belt for camshaft drive: check
for damage and check tension (5-cylin-
der diesel and TDI engines)
- Remove upper toothed belt cover.
- Check condition of toothed belt:
- Cracks, cross-sectional fractures
- Layer separation (base, cord strands)
- Base break-up
- Fraying of cord strands
- Surface cracks (plastic outer layer)
- Traces of oil and grease
Important
Faults found must be rectified (repair meas-
ure).
Vehicles > 1994:
- Check that toothed belt runs centrally on cam-
shaft sprocket.
Note:
If the toothed belt runs on one side of the sprocket,
this means that the lower idler wheel is not pressed
in straight and should be replaced (repair measure).
- Check tension of toothed belt:
Special tools required
♦ V-belt and toothed belt test unit VW 210
82
- Press in toothed belt firmly by hand between
camshaft sprocket and injection pump sprocket
to equalise tension.
- Measure tension of toothed belt using tester VW
210.
- Specification: on scale 12 ... 13
- Adjust toothed belt tension (repair measure) if the
reading does not match the specification (too
high or too low):
=> 5-cyl. Diesel Engine (2.4 ltr Engine), Mechanical
Components; Repair group 13; Dismantling and as-
sembling engine; Removing and installing toothed
belt for camshaft
=> 5-cyl. Diesel Engine (2.5 ltr Engine), Mechanical
Components; Repair group 13; Dismantling and as-
sembling engine; Removing and installing toothed
belt for camshaft
Vehicles 1995 >:
- Check tension of toothed belt:
83
- The two arrows must be aligned (max. distance
3 mm)
- If the markings are not opposite each other adjust
the tension of the toothed belt:
=> 5-cyl. Diesel Engine (2.5 ltr Engine), Mechanical
Components; Repair group 13; Dismantling and as-
sembling engine; Removing and installing toothed
belt for camshaft
84
Toothed belt for injection pump: check
for damage and check tension (5-cyl. TDI
engines), tension toothed belt
Special tools required
♦ Tensioner 3303
Vehicles > 1994:
- Remove rear toothed belt cover.
Vehicles 1995 >:
- Remove engine cover => Page 40.
All models:
- Check condition of toothed belt:
- Cracks, cross-sectional fractures
- Layer separation (base, cord strands)
- Base break-up
- Fraying of cord strands
- Surface cracks (plastic outer layer)
- Traces of oil and grease
Important
Faults found must be rectified (repair meas-
ure).
85
- Check tension of toothed belt for injection pump.
Vehicles 1995 >:
- Unscrew nut -A- on rear toothed belt guard for in-
jection pump drive.
- Push toothed belt guard and sleeve -B- to rear.
All models:
- Hook in spring of tensioner 3303.
Note:
In order to attach the tensioner on vehicles 1995>
without removing the stud, first file out a section of
the tensioner, as shown in the illustration (shaded
area).
86
- With tensioner 3303 -Item 1- hooked in position,
loosen nut -2- of tensioning roller.
- Move the tensioning roller by hand to check that
it moves easily; free the roller if necessary.
Note:
When the tensioning roller is released, the spring of
the tensioner automatically sets the belt to the cor-
rect tension.
- Check gap -A- at stop for tensioning roller.
Important
If gap A = 0 mm (tensioning roller lever against
stop) the toothed belt must be replaced (repair
measure).
87
- Tighten nut -2- on tensioning roller.
- Remove tensioner 3303 -Item 1-
Tightening torque Nm
Tensioning roller nut 45
88
Toothed belt for camshaft drive: check
for damage (2.6l 2V and 2.8l 2V engines
only)
- Remove engine cover => Page 34
- Remove upper toothed belt cover.
- Check condition of toothed belt:
- Cracks, cross-sectional fractures
- Layer separation (base, cord strands)
- Base break-up
- Fraying of cord strands
- Surface cracks (plastic outer layer)
- Traces of oil and grease
Important
Faults found must be rectified (repair meas-
ure).
89
Toothed belt: replace
Toothed belt: replace (4-cyl. petrol engines)
- Removing and installing toothed belt:
=> 4-cylinder Engine (2-valve), Mechanical Compon-
ents; Repair group 13; Dismantling and assembling
engine
=> 4-cylinder Injection Engine (4-valve), Mechanical
Components; Repair group 13; Dismantling and as-
sembling engine
Toothed belt: Replace (5-cyl. petrol engines)
- Removing and installing toothed belt:
=> 5-cylinder Engine (2-valve), Mechanical Compon-
ents; Repair group 13; Dismantling and assembling
engine
=> 5-cylinder Injection Engine (4-valve), Mechanical
Components; Repair group 13; Dismantling and as-
sembling engine
4-cylinder 5V 1.8 litre petrol engines
- Removing and installing toothed belt
=> 4-cyl. Engine (5-valve), Mechanical Components;
Repair group 13; Dismantling and assembling engine
Toothed belt and tensioning roller: replace (V6 -
5V engines)
- Removing and installing toothed belt, replacing
toothed belt tensioning roller:
90
=> 6-cylinder Engine (5-valve), Mechanical Compon-
ents; Repair group 13; Dismantling and assembling
cylinder crankcase, crank shaft and flywheel
Ribbed belt: replace (V8 engines)
=> 8-cylinder Engine, Mechanical Components; Re-
pair group 15; Cylinder head, valve gear; Removing
and installing ribbed belt
Toothed belt: replace (V8 engines)
=> 8-cylinder Engine, Mechanical Components; Re-
pair group 15; Cylinder head, valve gear; Removing
and installing toothed belt
Toothed belt for camshaft drive and tensioning
roller: replace (4-cyl. TDI engines)
- Removing and installing toothed belt, replacing
toothed belt tensioning roller:
=> 4-cyl. Diesel Direct Injection Engine (TDI), Mech-
anical Components; Repair group 13; Dismantling
and assembling engine
- Dynamically checking and adjusting commence-
ment of injection:
=> Diesel Direct Injection and Glow Plug System
(TDI 4-cylinder); Repair group 23; Servicing diesel dir-
ect injection system
91
Toothed belt for camshaft and injection pump:
replace (5-cylinder diesel engines)
=> 5-cyl. Diesel Engine (2.4 ltr Engine), Mechanical
Components; Repair group 13; Dismantling and as-
sembling engine; Removing and installing toothed
belt for camshaft, and toothed belt for injection
pump
- Dynamically checking and adjusting commence-
ment of injection.
=> Diesel Injection and Glow Plug System (2.4 l en-
gine); Repair group 23; Servicing diesel injection sys-
tem
Toothed belt for camshaft and injection pump:
replace: (5-cylinder TDI engines)
=> 5-cyl. Diesel Engine (2.5 ltr Engine), Mechanical
Components; Repair group 13; Dismantling and as-
sembling engine; Removing and installing toothed
belt for camshaft, and toothed belt for injection
pump
92
- Dynamically checking and adjusting commence-
ment of injection:
=> Diesel Direct Injection and Glow Plug System
(TDI 5-cylinder); Repair group 23; Dynamically check-
ing and adjusting commencement of injection
Filling in toothed belt renewal sticker - all
vehicles
- Fill in toothed belt renewal sticker -arrow- on lock
carrier; if necessary, attach a new sticker.
Manual gearbox/final drive: check oil
level and top up if necessary
5-speed manual gearbox 012, front-wheel drive
Special tools required
♦ Socket attachment 3357
or
♦ 17 mm hexagon socket attachment
Notes:
♦ The vehicle must be absolutely horizontal when
checking gearbox oil level. This work is best per-
formed over an inspection pit or using a 4 -
column lifting platform.
♦ The oil filler plug is on the left of the gearbox be-
low the speedometer sender; it may be con-
cealed by the heat shield for the drive shaft.
93
♦ Depending on the version fitted, use either spe-
cial tool 3357 or a 17 mm Allen key to loosen
the oil filler plug.
- Unscrew oil filler plug (arrow) to check oil level.
- Check oil level using a shop-built tool, e.g. a piece
of angled wire.
- Specification: oil level 7 mm below bottom edge
of oil filler hole
Note:
The oil can be filled up to the bottom edge of the oil
filler hole when servicing.
Important
If the oil level is below the range specified, the
gearbox must be checked for leaks (repair
measure). It is then not sufficient to merely
top up the fluid.
- If there are no leaks in the gearbox, top up with
SAE 75 W 90 (synthetic fluid), specification "G
052 911 A".
- Fit oil filler plug.
Tightening torque Nm
Oil filler plug 25
5-speed and 6-speed manual gearbox 01E, front
wheel drive
Notes:
94
♦ The vehicle must be absolutely horizontal when
checking gearbox oil level. This work is best per-
formed over an inspection pit or using a 4 -
column lifting platform.
♦ The prescribed oil level is to be adhered to ex-
actly; the gearbox reacts very sensitively to over-
filling.
♦ There are two different procedures for checking
the gearbox oil level according to the type of fi-
nal drive cover fitted.
Older version: oil filler hole behind flange shaft.
Newer version: oil filler hole in front of flange
shaft.
Older version:
- Remove oil filler plug -A- (behind flange shaft) to
check gearbox oil level.
- Check oil level using a shop-built tool, e.g. a piece
of angled wire.
- Specification: oil level 6 mm below bottom edge
of oil filler hole
95
Newer version:
- Remove oil filler plug -B- (in front of flange shaft)
to check gearbox oil level.
- Specification: oil level up to lower edge of filler
hole
All models:
Important
If the oil level is below the range specified, the
gearbox must be checked for leaks (repair
measure). It is then not sufficient to merely
top up the fluid.
- If there are no leaks in the gearbox, top up with
SAE 75 W 90 (synthetic fluid), specification "G
052 911 A".
- Fit oil filler plug.
Tightening torque Nm
Oil filler plug 40
5-speed manual gearbox 01A, four-wheel drive
Special tools required
♦ Socket attachment 3357
or
♦ 17 mm hexagon socket attachment
Notes:
96
♦ The oil filler plug is on the left of the gearbox be-
low the speedometer sender; it may be con-
cealed by the heat shield for the drive shaft.
♦ Depending on the version fitted, use either spe-
cial tool 3357 or a 17 mm Allen key to loosen
the oil filler plug.
- Unscrew oil filler plug (arrow) to check oil level.
- Specification: oil level up to lower edge of filler
hole
Important
If the oil level is below the range specified, the
gearbox must be checked for leaks (repair
measure). It is then not sufficient to merely
top up the fluid.
- If there are no leaks in the gearbox, top up with
SAE 75 W 90 (synthetic fluid), specification "G
052 911 A".
- Fit oil filler plug.
Tightening torque Nm
Oil filler plug 25
5-speed and 6-speed manual gearbox 01E, four-
wheel drive
Notes:
97
♦ The vehicle must be absolutely horizontal when
checking gearbox oil level. This work is best per-
formed over an inspection pit or using a 4 -
column lifting platform.
♦ The prescribed oil level is to be adhered to ex-
actly; the gearbox reacts very sensitively to over-
filling.
♦ There are two different procedures for checking
the gearbox oil level according to the type of fi-
nal drive cover fitted.
Older version: oil filler hole behind flange shaft.
Newer version: oil filler hole in front of flange
shaft.
Older version:
- Remove oil filler plug -A- (behind flange shaft) to
check gearbox oil level.
- Check oil level using a shop-built tool, e.g. a piece
of angled wire.
- Specification: oil level 7 mm below bottom edge
of oil filler hole
98
Newer version:
- Remove oil filler plug -B- (in front of flange shaft)
to check gearbox oil level.
- Check oil level using a shop-built tool, e.g. a piece
of angled wire.
- Specification: oil level 1 mm below bottom edge
of oil filler hole
All models:
Important
If the oil level is below the range specified, the
gearbox must be checked for leaks (repair
measure). It is then not sufficient to merely
top up the fluid.
- If there are no leaks in the gearbox, top up with
SAE 75 W 90 (synthetic fluid), specification "G
052 911 A".
- Fit oil filler plug.
Tightening torque Nm
Oil filler plug 40
99
Final drive (automatic gearbox): check
oil level and top up if necessary
Automatic gearbox 097, 01N
- Unscrew oil filler plug -arrow-.
- Specification: oil level up to lower edge of filler
hole
Important
If the oil level is below the range specified, the
final drive must be checked for leaks (repair
measure). It is then not sufficient to merely
top up the fluid.
- If the final drive has no leaks top up with SAE 75
W 90 (synthetic oil) specification "G 052 145 A".
- Fit oil filler plug.
Tightening torque Nm
Oil filler plug 25
- Fill in sticker for final drive oil check => Page 103.
Automatic gearbox 01K, front wheel drive
100
01F four-wheel drive
- Unscrew oil filler plug -arrow-.
- Specification: oil level up to lower edge of filler
hole
Important
If the oil level is below the range specified, the
final drive must be checked for leaks (repair
measure). It is then not sufficient to merely
top up the fluid.
- If the final drive has no leaks top up with SAE 75
W 90 (synthetic oil) specification "G 052 145 A".
- Fit oil filler plug.
Tightening torque Nm
Oil filler plug 25
- Fill in sticker for final drive oil check => Page 103.
101
Automatic gearbox 018; four-wheel drive
- Unscrew oil filler plug -arrow-.
- Specification: oil level up to lower edge of filler
hole
Important
If the oil level is below the range specified, the
final drive must be checked for leaks (repair
measure). It is then not sufficient to merely
top up the fluid.
- If the final drive has no leaks top up with SAE 75
W 90 (synthetic oil) specification "G 052 145 A".
- Fit oil filler plug.
Tightening torque Nm
Oil filler plug 25
- Fill in sticker for final drive oil check => Page 103.
102
Filling in sticker for final drive oil check - all
vehicles
- Fill in sticker for final drive oil check -arrow- on
lock carrier; if necessary, attach a new sticker.
103
Engine oil: drain or extract, change oil
filter
Special tools required
♦ Oil filter spanner 3417
(4-cyl. petrol engines)
♦ Strap wrench Hazet 2171 - 1 (5 - cyl. petrol en-
gines, V6-engines, 4-cyl. TDI engines, 5-cyl. dies-
el and TDI engines)
♦ Socket attachment, long, 36 A/F
♦ Oil extractor V.A.G 1307 A or V.A.G 1358 A
Note:
Observe environmental requirements for disposal.
- Remove noise insulation => Page 64.
4-cyl. petrol engines:
- Loosen oil filter - arrow - with oil filter spanner
3417.
5 - cyl. petrol engines, 4 - cyl. TDI engines, 5 - cyl.
diesel and TDI engines:
- Loosen oil filter with strap wrench (e.g. Hazet
2171-1).
104
V6 engines:
- Loosen oil filter -arrow- strap wrench (e.g. Hazet
2171-1).
V8 engines:
- Loosen oil filter -arrow- with socket attachment
30 mm A/F.
All models:
- Remove oil filter.
- Unscrew oil drain plug or extract engine oil.
- Clean sealing surface on engine for oil filter.
- Lightly lubricate rubber seal.
- Screw in new filter and tighten.
Notes:
Note the fitting instructions on the oil filter.
For engines with oil cooler
105
Important
After replacement of oil filter cartridge, check
clearance of hoses from oil cooler to adjacent
components; if necessary correct oil cooler po-
sition.
- Screw in oil drain plug with new seal.
- Top up engine oil, specifications => Page 119.
- Observe instructions for turbo engines => Page
121.
- Note different oil specifications for Audi S6 with
V8 engine AHK => Page 121.
Tightening torques Nm
Oil drain plug 4- and 5-cyl.-engines 30
Oil drain plug V6 - 2V engines: 40
Oil drain plug V6 - 5V engines: 30
Oil drain plugs V8 engines 35
106
Brake system: visual check for leaks and
damage
- Check the following components for leaks and
damage:
- Brake master cylinder
- Brake servo
- ABS hydraulic unit
- Brake calipers
- Brake pressure regulator
- Ensure that brake hoses are not twisted.
- Ensure that brake hoses do not touch any vehicle
components when steering is on full lock.
- Check brake hoses for porosity, blistering and
brittleness.
- Check brake hoses and pipes for chafing.
- Check brake pipe connections and mountings for
correct seating, leaks and corrosion.
Important
Faults found must be rectified (repair meas-
ure).
107
Brake pads: check thickness
Front disc brake pads:
Important
If the pad thickness is down to 7 mm (includ-
ing backing plate), the disc brake pads have
reached their wear limit and must be replaced
(repair measure). Please inform the customer.
- Determine thickness of outer pads by checking
visually (with help of electric torch/flashlight
through cut-out in wheel).
- Determine thickness of inner pads by checking
visually (with help of electric torch/flashlight and
mirror).
Notes:
♦ If the brake pads are not visible because of the
type of wheel rims fitted, remove front wheels.
♦ Before removing the wheels mark the position
of each wheel in relation to the brake disc and
mount the wheels in the same position after
completing the check.
♦ Observe notes on wheel bolts when mounting
the front wheels => Page 115.
108
Audi 100, Audi A6:
- a -Pad thickness including backing plate
- Wear limit: 7 mm
Audi S4 (5 cyl.) > 1993:
- a -Pad thickness including backing plate
- Wear limit: 7 mm
109
Audi S4 (5 cyl.) 1994>, Audi S4 (V8), Audi S6:
- a -Pad thickness including backing plate
- Wear limit: 7 mm
Rear disc brake pads:
Important
If the pad thickness is down to 7 mm (includ-
ing backing plate), the disc brake pads have
reached their wear limit and must be replaced
(repair measure). Please inform the customer.
- Determine thickness of outer pads by checking
visually (with help of electric torch/flashlight
through cut-out in wheel).
- Determine thickness of inner pads by checking
visually (with help of electric torch/flashlight and
mirror).
110
- a -Pad thickness including backing plate
- Wear limit: 7 mm
Notes:
♦ If the brake pads are not visible because of the
type of wheel rims fitted, remove rear wheels.
♦ Before removing the wheels mark the position
of each wheel in relation to the brake disc and
mount the wheels in the same position after
completing the check.
♦ Observe notes on wheel bolts when mounting
the rear wheels => Page 115.
Rear drum brake linings:
- Pull plug out of inspection hole in backplate -ar-
row-.
- Determine thickness of brake linings by checking
visually, using an electric torch (flashlight).
- a -Lining thickness without brake shoe
- Wear limit: 2.5 mm
Important
If the pad thickness is down to 2.5 mm (not in-
cluding backing plate), the drum brake linings
have reached their wear limit and must be re-
placed (repair measure). Please inform the cus-
tomer.
111
Underseal: visual check for damage
- When performing visual check, check underbody,
wheel housings and side members.
Important
Faults found must be rectified (repair meas-
ure).
Track rod ends: check play, attachment
and protective boots
Note:
The test must be made with vehicle raised on a lift-
ing platform (wheels free to move).
- Check play by moving track rods and wheels.
- There should be no play
- Check that lock nuts are secure (40 Nm).
- 1 -Lock nut on wheel side, right-hand thread
- 2 -Lock nut on track rod side, left-hand thread
- Check protective boot - arrow - for damage and
correct seating.
112
Tyres: check and correct condition, wear
pattern, tread depth and inflation pres-
sures
Notes:
♦ In the interests of driving safety, only tyres of
the same type and tread pattern should be fitted
on a vehicle.
♦ On four wheel drive vehicle tyres of the same
type and tread pattern must be used. Otherwise
the centre differential may be damaged.
- Check tyre tread and side walls for damage and
remove any foreign bodies.
- Check tyres for scuffing, one-sided wear, porous
side walls, cuts and fractures.
Important
The customer must be informed of any de-
fects.
Checking tyre wear pattern
- The wear pattern of the front tyres indicates
whether the toe and camber have to be checked
- Feathering on tread indicates incorrect toe set-
ting.
- One-sided tread wear is mainly caused by incor-
rect camber.
113
Note:
If the above types of wear are found, check wheel
alignment to determine the cause (repair measure).
Checking tyre tread depth
- Minimum permissible tread depth: 1.6 mm
Notes:
♦ This value may vary for individual countries ac-
cording to legislation.
♦ The minimum tread depth is reached when the
tyres have worn down level with the 1.6 mm
high tread wear indicators - arrows- positioned at
intervals around the tyre.
♦ If the tread depth is approaching the minimum
permissible tread depth, the customer must be
informed.
Inflating to correct pressures
The correct inflation pressures for summer tyres are
listed on the sticker on the inside of the tank flap.
Notes:
♦ Please note that the inflation pressures listed on
the sticker apply to cold tyres. When the tyres
are warm, the actual pressures will be higher,
but must not be reduced.
♦ When using winter tyres, pressures should be
increased by 0.2 bar.
Spare wheel
114
• Spare wheel with standard-size tyre
- Inflate to the maximum pressure specified for the
vehicle.
• Temporary (compact) spare wheel: The correct
inflation pressure is indicated on the side wall.
Notes:
♦ The tyre valves must be closed with dust caps.
Otherwise, dirt can obstruct the valve pin and
cause loss of air.
♦ On vehicles with steel rims and wheel covers,
check the tyre valve extensions. Damage and
dirt can cause leaks. Replace if necessary.
Wheel bolts: tighten to specified torque
Wheel cover
Puller - 1 - for removing the wheel cover is in the
vehicle tool kit.
115
Trim cap
- On vehicles with light-alloy wheels and trim caps
insert a screwdriver in the recess and lever the
trim cap off the wheel rim.
Wheel bolt locks
- Pull trim cap off wheel bolt lock.
- On wheel rims with recessed wheel bolts, insert
the hook -2- at the side of the bolt, turn it slightly
and pull the cap off.
- Turn key -1- anti-clockwise in wheel bolt lock and
remove together with wheel bolt lock.
- To re-install, push wheel bolt lock as far as it will
go onto wheel bolt.
- Turn key clockwise in lock and remove key.
- When refitting the cap, ensure that it engages all
the way round.
Note:
Ensure that the wheel bolts are tightened in a diag-
onal sequence to the following tightening torque:
Tightening torque Nm
Wheel bolts 120
116
Correct installation of wheels
- When fitting the road wheels note the following
points to ensure that the wheels remain secure at
all times.
• Always tighten the wheel bolts to the specified
torque, excessive torque can distort the wheel
bolt seats in the rim.
• When fitting a wheel do not torque down the
first wheel bolt immediately (e.g. with an impact
wrench), as this would prevent the other bolts
from centring the wheel properly when they are
screwed in. The rim could then come loose even
though the bolts have been tightened to the spe-
cified torque.
• Before installing the wheels examine the seats
of the wheel bolts and the contact surfaces
between the rims and the hubs for rust and cor-
rosion. Clean off these parts if necessary other-
wise this can affect the clamping force of the
bolts after installation and the rims can come
loose.
117
Important
♦ If the points listed above are not observed
the wheel mountings can come loose and
the wheel bolt seats can become distorted.
♦ This distortion may be very slight and not
visible to the naked eye.
♦ Even this slight distortion of the wheel
bolt seats can prevent the rims from being
held firmly and the wheels will come loose
repeatedly.
Engine oil: fill
The engine is filled with a high quality multigrade oil
at the factory which can be used all year round, ex-
cept in extremely cold climates.
Viscosity grades
Note:
The oil does not need changing for brief variations of
outside temperature beyond the temperature ranges
shown.
118
Viscosity grades for petrol, diesel and TDI en-
gines (but not for Audi S6 with V8 engine AHK):
Select the viscosity grade of the oil according to the
chart.
- A - Multigrade high lubricity oils, specification
=> Page 120
- B - Multigrade oils, specification => Page 120
Viscosity grades for Audi S6 with V8 engine
AHK:
Select the viscosity gradeof the oil according to the
chart 1).
- A - Multigrade high lubricity oils, specification
=> Page 121
1) If these oils are not available engine oils with
other viscosity grades may be used as an emer-
gency measure as long as they conform to VW
standard 500 00 => Page 121.
Oil specifications
The specifications listed here should appear on the
container - either singly or together with other spe-ci-
fications.
119
Note:
When topping up, different types of oil may be
mixed if necessary.
Oil specification for petrol engines (but not for
Audi S6 with V8 engine AHK) and diesel engines
(but not for TDI engines):
- A - High lubricity multigrade oils, specification
VW 500 00 1)
High - lubricity multigrade oils, specification VW
502 00 2)
- B - Multigrade oils, specification VW 501 01
1)
- - Multigrade oils, Specification API-SF 3)or API-
SG 3)
1) The date given after the VW specification must
not be earlier than 10.97.
2) These oils are particularly suitable for tur-
bocharged petrol engines.
3) These oils should only be used if the approved
engine oils are not available.
Oil specifications for TDI engines:
- A - High-lubricity multigrade oils, specification
VW 500 00 1) (only in combination with specifica-
tion VW 505 00)
- B - Multigrade oils, specification VW 505 00
1)
- - Multigrade oils, specification VW 501 01 1)
(only in conjunction with specification VW 505 00)
120
- - Multigrade oils, specification API-CD (should
only be used for emergency topping up)
1) The date given after the VW specification must
not be earlier than 10.97.
Oil specifications for Audi S6 with V8 engine
AHK:
- A - High lubricity multigrade oils, specification
VW 500 00 1)
1) The date given after the VW specification must
not be earlier than 10.97.
- Top up engine oil.
Capacities with filter replacement:
=> ELSA Maintenance table
Engines with turbocharger:
- When the engine oil and oil filter have been
changed, it is important to note the following
after starting the engine for the first time:
- The engine must only run at idling speed until
the oil pressure warning lamp in the dash panel
insert goes out.Do not press the accelerat-
or!This could cause severe damage to the tur-
bocharger.
- The full oil pressure is only reached when the
warning lamp goes out, and the accelerator can
then be pressed.
All models:
- Finally, check the engine oil level => Page 122.
121
Engine: check oil level
Test requirements:
• Engine oil temperature at least 60 °C
• Vehicle must be level (horizontal)
• Wait a few minutes after switching off the en-
gine to allow the oil to flow back into the sump.
- Pull out the dipstick, wipe with a clean cloth and
insert again to stop.
- Pull out the dipstick again and read off the oil
level.
Markings on oil dipstick:
- a -Oilmust not be topped up.
- b -Oil may be topped up. The oil level may rise
as far as area -a- after topping up.
- c -Oilmustbe topped up. The oil level is suffi-
cient if somewhere in area -b- (grooved area) after
topping up.
Note:
The oil level must not be above marking -a- on the
dipstick.
122
Automatic gearbox: change ATF (except
01N gearbox)
Engine Gearbox Page
4- and 5-cyl. engines > 12.94
V6 engines (front-wheel drive) >
02.92
097 124
5 cyl. TDI engines > 05.94
V6 engines (front-wheel drive)
03.92 > 05.94
01K 128
5 cyl. TDI engines 06.94 >
V6 engines (front-wheel drive)
06.94 >
01K 133
5-cyl. 4V engines > 05.94
V6 engines (four-wheel drive) >
05.94
01F 128
5-cyl. 4V engines 06.94 >
V6 engines (four-wheel drive)
06.94 >
01F 133
V8 engines 018 137
Notes:
♦ Use only ATF with the part no. G 052 162 A.
(colour: clear/yellow). Do not use any additives!
♦ The engine must not be started or towed
without ATF in gearbox.
♦ When filling is started, the ATF temperature
must not be higher than 35 °C.
♦ Observe environmental requirements for dispos-
al.
123
Special tools, testers and auxiliary items required
♦ Drip tray V.A.G 1306
♦ Oil extractor V.A.G 1358 A with oil suction probe
V.A.G 1358 A/1 (automatic gearbox 097 only)
♦ Fault reader V.A.G 1551 with diagnostic cable
V.A.G 1551/1
♦ ATF filling system V.A.G 1924 and protective
goggles
(not for automatic gearbox 097)
Automatic gearbox 097
Draining ATF
- Draw off ATF with oil extractor V.A.G 1358 A with
oil suction probe 1358/A 1.
or
- Raise vehicle.
- Place drip tray V.A.G 1306 underneath the gear-
box.
124
- Unscrew union nut on lower ATF filler pipe -5-
and pull filler pipe out of oil pan.
- Allow the ATF to drain out.
- Re - attach ATF filler pipe: tightening torque 80
Nm.
Filling ATF
- First fill approx. 3.0 litres of ATF into the filler pipe
using a funnel.
- Move selector lever to position "P".
- Start engine and run at idling speed.
- With the engine idling press the brake pedal and
shift the selector lever through all the selector
lever positions leaving the selector lever 2 ... 3
seconds in each position.
- Move selector lever to position "P".
- Pull out ATF dipstick and wipe clean using a lint-
free cloth.
- Insert the ATF dipstick all the way into the ATF
filler pipe and pull it out again.
125
- Check ATF level on dipstick.
- ATF should be filled up to the 20 °C-mark when
cold.
- Switch ignition off.
Checking ATF level
Test requirements:
• Gearbox not in emergency running mode, ATF
temperature between 50 ... 70 °C.
• Vehicle must be level (horizontal)
• Set the selector lever to "P".
• The air conditioner and heating system must be
switched off.
- Connect V.A.G 1551 => Page 23.
- Start engine and run at idling speed.
- Enter "1" to select "Rapid data transfer".
- Enter "02" for address word "Gearbox electronics"
and confirm entry with Q key.
- Press ⇒ key to continue.
- Enter "08" to select the function "Reading meas-
ured value block" and confirm entry with Q key.
Reading measured value block Q
Enter display group number XXX
Indicated on display
- Enter "005" to select display group number "005"
and confirm entry with Q key.
Read measured value block 5 ⇒
1 2 3 4
Indicated on display
- Read off ATF temperature in display zone 1.
- When the ATF has reached a temperature of
about. 50 °C, pull out the ATF dipstick and wipe it
clean using a lint-free cloth.
126
- Insert the ATF dipstick all the way into the ATF
filler pipe and pull it out again.
- Check ATF level on dipstick.
• If the ATF level is between the min. and max.
markings at a temperature of 50 ... 70 °C, the
ATF level is OK.
Notes:
♦ The ATF level must not be checked at temperat-
ures above 70 °C. If necessary wait for the ATF
to cool down again.
♦ The markings on the ATF dipstick are for an ATF
temperature of 60°C.
Important
An insufficient ATF filling as well as filling to
excess affects the function of the gearbox.
• If ATF level is too low:
- Fill up with ATF using a clean funnel.
Note:
Use only ATF "G 052 162 A." (colour: clear/yellow).
Do not use any additives!
- With vehicle stationary and engine running, move
selector lever through all selector lever positions.
- Check ATF level again at test temperature.
• If ATF level is too high:
127
- Draw off excess ATF with oil extractor V.A.G
1358 A and oil suction probe 1358/A 1.
- Check ATF level again at test temperature.
Automatic gearbox 01K, front wheel drive
01F four-wheel drive > 1994
Draining ATF
- Raise vehicle.
- Place drip tray V.A.G 1306 underneath the gear-
box.
- Unscrew ATF drain plug -arrow 1-.
- Allow the ATF to drain out.
Filling ATF
- Fit ATF drain plug with new seal and screw in.
- Pull sealing cap -arrow- off ATF filler pipe.
- First put approx. 2.7 litres of ATF into the filler
pipe using a funnel.
- Move selector lever to position "P".
- Start engine and run at idling speed.
- With the engine idling press the brake pedal and
shift the selector lever through all the selector
lever positions leaving the selector lever 2 ... 3
seconds in each position.
- Move selector lever to position "P".
128
- Measure ATF level using ATF dipstick.
- For the following vehicles, check the ATF level
using the dipstick marked "02":
- All vehicles with V6 engines
- Audi S4 up to vehicle identification number 4A
RN 033 426
( > approx. 11.93)
Note:
Vehicles requiring "02" dipstick have "02" marked on
ATF filler pipe -arrow-.
- For the following vehicles, check the ATF level
using the dipstick marked "03":
- All with 5 cyl. TDI engine
- Audi S4 from vehicle identification number 4A
RN 033 427 (approx. 11.93 >)
Note:
Vehicles requiring "03" dipstick have "03" marked on
ATF filler pipe -arrow-.
- Use a lint - free cloth to wipe the ATF dipstick
clean.
- Insert the ATF dipstick all the way into the ATF
filler pipe and pull it out again.
- Check ATF level on dipstick.
129
- ATF should be filled up to the 20 °C mark when
cold.
- Switch ignition off.
Tightening torque Nm
ATF drain plug 40
Checking ATF level
Test requirements:
• Gearbox not in emergency running mode, ATF
temperature between 50 ... 70 °C.
• Vehicle must be level (horizontal)
• Set the selector lever to "P".
• The air conditioner and heating system must be
switched off.
- Connect V.A.G 1551 => Page 23.
- Start engine and run at idling speed.
- Enter "1" to select "Rapid data transfer".
- Enter "02" for address word "Gearbox electronics"
and confirm entry with Q key.
4A0927156AL AG4 01F 2.8l 5V RoW D26 ⇒
Coding 00001 WSC 06744
If following display appears (example):
- Check control unit identification.
Control unit identification containing code "01D".
- Press ⇒ key to continue.
- Enter "08" to select the function "Reading meas-
ured value block" and confirm entry with Q key.
Reading measured value block Q
Enter display group number XXX
Indicated on display
130
Maintenance audi 100
Maintenance audi 100
Maintenance audi 100
Maintenance audi 100
Maintenance audi 100
Maintenance audi 100
Maintenance audi 100
Maintenance audi 100
Maintenance audi 100
Maintenance audi 100
Maintenance audi 100
Maintenance audi 100
Maintenance audi 100
Maintenance audi 100
Maintenance audi 100
Maintenance audi 100
Maintenance audi 100
Maintenance audi 100
Maintenance audi 100
Maintenance audi 100
Maintenance audi 100
Maintenance audi 100
Maintenance audi 100
Maintenance audi 100
Maintenance audi 100
Maintenance audi 100
Maintenance audi 100
Maintenance audi 100
Maintenance audi 100
Maintenance audi 100
Maintenance audi 100
Maintenance audi 100
Maintenance audi 100
Maintenance audi 100
Maintenance audi 100
Maintenance audi 100
Maintenance audi 100
Maintenance audi 100
Maintenance audi 100
Maintenance audi 100
Maintenance audi 100
Maintenance audi 100
Maintenance audi 100
Maintenance audi 100
Maintenance audi 100
Maintenance audi 100
Maintenance audi 100
Maintenance audi 100
Maintenance audi 100
Maintenance audi 100
Maintenance audi 100
Maintenance audi 100
Maintenance audi 100
Maintenance audi 100
Maintenance audi 100
Maintenance audi 100

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Maintenance audi 100

  • 1. Service. 6 Maintenance Audi 100 1991 > Booklet No. 54: Audi 100 1991> Edition 01.98 Booklet Service Department. Technical Information
  • 2. Service. 6 Maintenance Audi 100 1991 > Booklet No. 54: Audi 100 1991> Edition 01.98 Booklet Technical Bulletins Oil Change Service Inspection Service Lifting the vehicle Tow-starting/towing Technical Information should always be available to all foremen and mechanics, because their com- pliance with the instructions given is essential to ensure vehicle roadworthiness and safety. In the normal safety precautions to be observed when working on motor vehicles are also applicable. All rights reserved. No reproduction without prior agreement from publisher. Printed in Germany Copyright © 1998 Audi AG, Ingolstadt 005.5251.50.20
  • 3. Contents Page - Survey of engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Oil Change Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Inspection Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - Windscreen wiper and washer system and headlight washer system: adjust washer jet settings and check function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 - Windscreen washer system: check washer jet settings and adjust if necessary . . . . . . . . . . . . . . . . . . . . . . . 15 - Headlight washer system: check washer jet settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 - Wiper blades: check park position and check for damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 - Self-diagnosis: interrogate fault memory with fault reader V.A.G 1551 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 - Service interval display: reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 - Door arresters and lock cylinders: lubricate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 - Sun roof: check function, clean guide rails and spray with lubricating spray . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 - Removing plenum chamber cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 - Battery: check electrolyte level and top up with distilled water if necessary . . . . . . . . . . . . . . . . . . . . . . . . . . 32 - Removing engine cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 - Engine (from above and below) and engine compartment: visual check for leaks and damage . . . . . . . . . . . . 38 - Windscreen / headlight washer system: top up fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 - Cooling system: check antifreeze and top up coolant if necessary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 - Coolant G11: Change (V8 petrol engines only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 - Air cleaner: clean housing and replace filter element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 - Spark plugs: replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 - Hydraulic system: check for leaks, check fluid level and top up hydraulic fluid if necessary . . . . . . . . . . . . . . . 54 - Fuel filter: replace (diesel and TDI engines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 - Fuel filter: drain off water (Diesel and TDI engines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 - Dust and pollen filter: replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 - Plenum chamber and water drain valves: check for dirt and clean if necessary . . . . . . . . . . . . . . . . . . . . . . . . 63 - Noise insulation: remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 - V-belt: check for damage and check tension; adjust tension if necessary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 - V-belts: tensioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 - V-belt (not ribbed belt) for alternator: replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 - Ribbed belt: check for damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 - Ribbed belt: check tension; adjust if necessary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 - V-belt and ribbed belt: replace (4-cyl. 5V engines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 - Ribbed belt: replace (V6 engines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 - Toothed belt for camshaft drive: check for damage and measure toothed belt width (4-cyl. TDI engines) . . . . 81 - Toothed belt for camshaft drive: check for damage and check tension (5-cylinder diesel and TDI engines) . . . 82 - Toothed belt for injection pump: check for damage and check tension (5-cyl. TDI engines), tension toothed belt85 - Toothed belt for camshaft drive: check for damage (2.6l 2V and 2.8l 2V engines only) . . . . . . . . . . . . . . . . . . 89 - Toothed belt: replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 - Manual gearbox/final drive: check oil level and top up if necessary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 - Final drive (automatic gearbox): check oil level and top up if necessary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 - Engine oil: drain or extract, change oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104 - Brake system: visual check for leaks and damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 - Brake pads: check thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108 - Underseal: visual check for damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112 - Track rod ends: check play, attachment and protective boots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112 - Tyres: check and correct condition, wear pattern, tread depth and inflation pressures . . . . . . . . . . . . . . . . . . 113 - Wheel bolts: tighten to specified torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 - Engine oil: fill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118 - Engine: check oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122 - Automatic gearbox: change ATF (except 01N gearbox) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123 - Idling speed: check and adjust if necessary (2.4 ltr diesel AAS only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142 - Brake fluid level (depending on brake pad wear): checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144 - Brake fluid: change brake fluid (every 24 months) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146 - Headlights: check settings and adjust if necessary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150 - Test drive: perform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154 - Vehicle data sticker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155 - Engine code and engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158 Lifting the vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162 Tow-starting/towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164 - Arbeitsabläufe Benzinmotoren . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169 - Arbeitsabläufe Dieselmotoren . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
  • 4. - Abgasuntersuchung Deutschland . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171 - Arbeitsabläufe Benzinmotoren . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172 - Störgröße vorbereiten . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173 - Prüfgeräte . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177 - Prüfablauf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179 - Prüfung mit Fehlerspeicher-Abfrage (V.A.G 1551) zur Lambda-Regelkreisprüfung . . . . . . . . . . . . . . . . . . . . . . 189 - Prüfung ohne Fehlerspeicher-Abfrage (V.A.G 1551) zur Lambda-Regelkreisprüfung . . . . . . . . . . . . . . . . . . . . 190 - Arbeitsablauf Dieselmotoren . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231 - Prüfgeräte . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232 - Prüfablauf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
  • 5. Survey of engines 1 The order in which the individual operations are given has been tested and represents the optimum work- ing sequence. The sequence should therefore be followed to avoid unnecessary work interruptions. 1 The sequence of operations given is based on that specified for the Inspection Service, which is the type of service most frequently required. 1 Always inform the customer if faults or defects which need repairing are identified during the Inspection Service. Code ADA ABB ADR AAE ADW AAD ABK No of cylinders 4 4 4 4 4 4 4 Valves per cylinder 2 2 5 2 2 2 2 Capacity l 1.6 1.6 1.8 2.0 2.0 2.0 2.0 Output kW at rpm 74 6000 75 6100 92 5800 74 5500 79 5300 85 5400 85 5400 Torque Nm at rpm 130 3200 127 3700 173 3950 157 2750 160 3200 168 3200 166 3200 Bore øin mm 81.0 81.0 81.0 82.4 82.5 82.5 82.5 Stroke mm 77.4 77.4 86.4 92.8 92.8 92.8 92.8 Compression 10.5 10.0 10.3 9.3 9.0 10.3 10.5 1 Code ADA ABB ADR AAE ADW AAD ABK Injection/ Ignition Multi Point Injection K-Jetronic/ TSZ-h Motronic Mono- Motronic Digifant KE- Motronic Digifant RON at least 95 (unleaded) 2) 98 (unleaded or leaded) 3) 95 1) (unleaded) 91 (unleaded) 88 (unleaded or leaded) 95 1) (unleaded) 2) 95 1) (unleaded) 2) Hydraulic valve lifters X X X X X X X Self-diagnosis X - X X X X X Catalytic converter X / - 4) - X X - X / - 4) X / - 4) Lambda control X - X X X X X Exhaust emission test after 3, 5, 7, 9 ... years X X X X X X X 1) Regular unleaded petrol RON 91 can be used but will cause a slight loss of power. 2) Unleaded for vehicles with catalytic converter; unleaded or leaded for vehicles without catalytic converter. 3) When using Premium unleaded petrol 95 RON adjust ignition timing to 3 ± 1° before TDC. 4) Optional in some countries. 2
  • 6. Code ACE AAN AAR AFM ACZ ABC AEJ No of cylinders 4 5 5 6 6 6 6 Valves per cylinder 4 4 2 2 2 2 2 Capacity l 2.0 2.226 2.3 2.4 2.6 2.6 2.8 Output kW at rpm 103 5900 169 5900 98 5500 110 5800 102 5750 110 5750 120 5400 Torque Nm at rpm 185 4500 350 1950...3000 186 4000 210 3300 210 3500 225 3500 235 3000 Bore øin mm 82.5 81.0 82.5 81.0 82.5 82.5 82.5 Stroke mm 92.8 86.4 86.4 77.4 81.0 81.0 86.4 Compression 10.8 9.3 10.0 10.0 9.0 10.0 9.2 Injection/ Ignition KE- Motronic Motronic KE III- Jetronic/ VEZ Multi Point Fuel Injection Multi Point Fuel Injection Multi Point Fuel Injection Multi Point Injection RON at least 95 1) (unleaded) 95 or 98 (unleaded) 95 1) (unleaded) 95 (unleaded) 88 (unleaded or leaded) 95 1) (unleaded) 88 (unleaded or leaded) 1) Regular unleaded petrol RON 91 can be used but will cause a slight loss of power. 3 Code ACE AAN AAR AFM ACZ ABC AEJ CN at least - - - - - - - Hydraulic valve lifters X X X X X X X Self-diagnosis X X X X X X X Catalytic converter X X X X - X - Lambda control X X X X X X X Exhaust gas recircula- tion system - - - - - - - Turbo charging - X - - - - - Exhaust emission test after 3, 5, 7, 9 ... years X X X X X X X 4
  • 7. Code AAH ACK ABH AEC AHK 1Z AHU No of cylinders 6 6 8 8 8 4 4 Valves per cylinder 2 5 4 4 4 2 2 Capacity l 2.8 2.8 4.2 4.2 4.2 1.9 1.9 Output kW at rpm 128 5500 142 6000 206 5800 213 5800 240 6500 66 4000 66 4000 Torque Nm at rpm 250 5) 3000 280 3200 400 4000 400 4000 400 3500 202 1900 7) 202 1900 Bore øin mm 82.5 82.5 84.5 84.5 84.5 79.5 79.5 Stroke mm 86.4 86.4 93.0 93.0 93.0 95.5 95.5 Compression 10.3 10.6 10.6 10.8 11.6 19.5 19.5 Injection/ Ignition Multi Point Injection Motronic Motronic Motronic Motronic Diesel (direct injec- tion) Diesel (direct injec- tion) RON at least 98 5) (unleaded) 95 1) (unleaded) 98 6) (unleaded) 98 6) (unleaded) 98 6) (unleaded) - - 1) Regular unleaded petrol RON 91 can be used but will cause a slight loss of power. 5) If premium unleaded petrol 95 RON is used, there will be a reduction in torque (245 Nm at 3000 rpm). 6) Premium unleaded petrol RON 95 can be used but will cause a slight loss of power. 7) Vehicles with an airflow meter: 182 Nm at 2300 ... approx. 2500 rpm 5 Code AAH ACK ABH AEC AHK 1Z AHU CN at least - - - - - 45 45 Hydraulic valve lifters X X X X X X X Self-diagnosis X X X X X X X Catalytic converter X X X X X Oxidising catalytic converter Oxidising catalytic converter Lambda control X X X X X - - Exhaust gas recircula- tion system - - - - - X X Turbo charging - - - - - X X Exhaust emission test after 3, 5, 7, 9 ... years X X X X X X X 6
  • 8. Code AAS AAT ABP AEL No of cylinders 5 5 5 5 Valves per cylinder 2 2 2 2 Capacity l 2.4 2.5 2.5 2.5 Output kW at rpm 60 4400 85 4000 85 4000 103 4000 Torque Nm at rpm 164 2400...2500 265 2250 265 2250 290 1900 Bore øin mm 79.5 81.0 81.0 81.0 Stroke mm 95.5 95.5 95.5 95.5 Compression 23.0 20.5 20.5 20.5 Injection/ Ignition Diesel (swirl chamber) Diesel (direct injection) Diesel (direct injection) Diesel (direct injection) RON at least - - - - 7 Code AAS AAT ABP AEL CN at least 45 45 45 45 Hydraulic valve lifters X X X X Self-diagnosis - X X X Catalytic converter - Oxidising catalytic converter - Oxidising catalytic converter Lambda control - - - - Exhaust gas recirculation system - X X X Turbo charging - X X X Exhaust emission test after 3, 5, 7, 9 ... years X X X X 8
  • 9. Oil Change Service Work to be completed after every 7,500 km only for vehicles with diesel engines (engine code AAS) Page OIL 1) Work to be completed after every 15,000 km only for vehicles completing over 15,000 km a year Plenum chamber and water drain valves: Check for dirt and clean if necessary 63 Fuel filter: Drain water (diesel and TDI engines only) 58 Toothed belt for camshaft drive: check for damage and measure toothed belt width (4-cyl. TDI engines only) 81 Engine oil: drain or extract, change oil filter 104 Brake pads: check thickness of disc brake pads 108 Engine oil: fill 118 Service interval display: reset (Audi A6 / S6 only) 24 Audi service sticker: enter date for next service (and for brake fluid change) on sticker and affix on left of dash panel or on door post (B-pillar) 1) Inspection due according to service interval display (Audi A6 / S6 only) 9 Inspection Service Inspec- tion 1) Interval Work to be completed Page In 1 Every 12 months Jobs without -/-- positions In 1 Every 30,000 km Jobs required every 12 months including -positions In 1 One-off inspection after 60,000 km Toothed belt for camshaft drive: replace (5-cyl. TDI engines > 1994 only) In 1 Every 60,000 km Jobs required every 12 months including -/--positions In 1 Every 90,000 km In addition to Inspection Service: Ribbed belt: replace (V6 engines >1994 only) Toothed belt for camshaft drive and tensioning roller: replace (4-cyl. TDI engines only) 91 In 1 Every 120,000 km In addition to Inspection Service: V-belt and ribbed belt: replace (4-cylinder 5V engines) Ribbed belt: replace (V6 engines >1995 only) Toothed belt: replace (4 and 5-cyl. petrol engines) Toothed belt for camshaft and injection pump: replace (5-cyl. diesel engines) Toothed belt for camshaft and injection pump: replace (5-cyl. TDI engines) Toothed belt and tensioning roller: Replace (V6 5-valve engines only) Toothed belt and ribbed belt: Replace (V8 engines only) 91 10
  • 10. Inspec- tion 1) Interval Work to be completed Page In 2 Every 24 months In addition to Inspection Service: Brake fluid: change 146 In 1 Every 36 months In addition to Inspection Service: Coolant G11: Renew (V8 petrol engines only) Coolant "G12" need not be changed, even after changing from "G11" to "G12" coolant 44 After the first 36 months, then every 24 months Exhaust emissions test 169 Work to be completed 5 1) Inspection due according to service interval display (Audi A6 / S6 only) Work to be completed Page Front and rear lights, turn signals, hazard warning lights, luggage compartment lights: check func- tion Interior lights and glove compartment light, warning lamps, horn: check function Windscreen wiper and washer system and headlight washer system: adjust washer jet settings and check function 15 Wiper blades: check park position and check for damage 18 Self-diagnosis: interrogate fault memory with fault reader V.A.G 1551 21 Service interval display: reset (Audi A6 / S6 only) 24 Door arresters and lock cylinders: lubricate 30 - Sun roof: check function, clean guide rails and spray with lubricating spray 31 Battery: check electrolyte level and top up with distilled water if necessary 32 11 Engine (from above) and engine compartment: visual check for leaks and damage 38 Windscreen / headlight washer system: top up fluid 39 Cooling system: check antifreeze and top up coolant if necessary 40 -- Air cleaner: clean housing and replace filter element (every 60,000 km or every 2 years, whichever comes first) 45 - Spark plugs: Replace (vehicles > 1993) 47 -- Spark plugs: Replace (vehicles 1994 >, every 60,000 km or every 3 years, whichever comes first) 47 Continued 5 - Hydraulic system: check for leaks and check fluid level, top up hydraulic fluid if necessary (vehicles > 1991 only) 54 -- Hydraulic system: check for leaks and check fluid level, top up hydraulic fluid if necessary (vehicles > 1992 only) 54 - Fuel filter: Replace (diesel and TDI engines only) 56 Fuel filter: Drain water (diesel and TDI engines only) 58 - Dust and pollen filter: replace (Audi 100 > 1992 with 2V1 => vehicle data sticker, Audi 100 1993 > 1994 without air conditioner, Audi A6 1995 >) 61 Plenum chamber and water drain valves: Check for dirt and clean if necessary 63 V-belt: check for damage and check tension; adjust tension if necessary 65 -- V-belt (not ribbed belt) for alternator: Replace (vehicles > 1993 only) 70 - Ribbed belt: check for damage (vehicles > 1994 only) 72 - Ribbed belt: check tension; adjust if necessary (4-and 5-cyl. 1993 engines only) 73 Toothed belt for camshaft drive: check for damage, measure toothed belt width (4-cyl. TDI engines only) 81 12
  • 11. - Toothed belt for camshaft drive: check for damage and check tension (5-cyl. diesel and TDI engines only) 82 - Toothed belt for injection pump: check for damage and check tension (5-cyl. TDI engines), adjust tension of toothed belt - Additional job 85 Continued 5 -- Toothed belt for camshaft drive: check for damage (2.6l 2V and 2.8l 2V engines only). 89 Engine (from below): visual check for leaks and damage 38 Gearbox, final drive, steering and protective boots: visual check for leaks and damage - Manual gearbox/final drive: check oil level and top up if necessary 93 -- Final drive (automatic gearbox): check oil level and top up if necessary 100 Engine oil: drain or extract, change oil filter 104 Brake system (from below): visual check for leaks and damage 107 Brake pads: check thickness 108 - Underseal: visual check for damage 112 Exhaust system: visual check for leaks and damage, check that parts are properly secured Track rod ends: check play, attachment and protective boots 112 Ball joints: check protective boots for leaks and damage Tyres (incl. spare wheel): check condition and wear pattern 113 Tyres (incl. spare wheel): check and record tread depths FL FR RR RL Spare 114 Tyres (incl. spare wheel): Inflating to correct pressures 114 Engine oil: fill 118 -- Automatic gearbox: change - ATF (additional job) (every 60,000 km or every 4 years, whichever comes first) 123 13 Idling speed: check and adjust if necessary (2.4 ltr diesel AAS only) 142 Continued 5 Brake fluid level (depending on brake pad wear): check 144 - Headlights: check settings and adjust if necessary 150 Audi service sticker: enter date for next service (and for brake fluid change) on sticker and affix on left of dash panel or on door post (B-pillar) Test drive: perform 154 14
  • 12. Windscreen wiper and washer system and headlight washer system: adjust washer jet settings and check function Note: If the wiper blades judder or make a noise when tested, check the contact angle of the wiper blades =>Page 19. Windscreen washer system: check washer jet settings and adjust if neces- sary Special tools required ♦ Windscreen wiper jet adjusting tool 3125 A with needle 3125/5 Note: Never use pins or other sharp objects as these will damage the water channels in the jet. Windscreen washer jet settings - Mark the four points on the windscreen with wa- ter-soluble ink. 15 Setting dimensions: ♦ Dimension a = 230 mm ♦ Dimension b = 280 mm ♦ Dimension c = 160 mm ♦ Dimension d = 480 mm Note: The setting dimensions are calculated from the outer edges of the windscreen. - Use the special tool 3125 A to aim the individual jets at the points marked. Notes: ♦ The setting dimensions give the values for the vehicle when moving. The spray from the jets will be slightly offset when stationary. ♦ If the jet of water is irregular or cannot be adjus- ted to the specified setting, replace the jet (re- pair measure). 16
  • 13. Rear window washer jet setting - Adjust the washer jet using special tool 3125 A so that the water jet is directed onto the rear win- dow within the dimension a = 280 mm above the wiper arm pivot mounting. 17 Headlight washer system: check washer jet settings The headlight washer jets are set by the manufac- turer and therefore do not require adjustment. Wiper blades: check park position and check for damage Park position for windscreen wiper blades - Switch windscreen wipers on and off and allow to return to the park position. - Check that the wiper blades are in the correct po- sition on the windscreen. - A - End of wiper blade on passenger's side at upper edge of dotted pattern. - B - Wiper blade on driver's side: a = 10 mm below upper edge of dotted pattern. Note: The positioning is symmetrically opposite for right - hand drive vehicles. - If necessary, loosen the wiper arm, align and tighten fastening nut. - Actuate flick wipe switch and check settings. Tightening torque Nm Wiper arms to pivot mountings 16 Park position for rear window wiper blade 18
  • 14. - Switch rear window wipers on and off and allow to return to the park position. - Check that the wiper blade is on upper edge of the dotted pattern on rear window. - If necessary, loosen the wiper arm, align and tighten fastening nut. Tightening torque Nm Wiper arm to pivot mounting 16 Contact angle of front wiper blades Note: Only check the contact angle when the wiper blades judder or make noises. Special tools required ♦ Wiper arm adjusting tool 3358 - Switch windscreen wipers on and off and allow to return to the park position. - Remove wiper blade. 19 - Insert wiper arm -2- in wiper arm adjusting tool 3358 and secure with locking screw -3-. - Compare angle indicated to specified value in table. Contact angle (specifications) Driver's side - 4° Passenger's side - 2° Tolerance ±0° - If necessary, adjust the contact angle to the spe- cified value as follows: - Place open ended spanner -1- (24 mm A/F) over adjusting tool and adjust angle of wiper arm -2- (arrows) according to specified values. - Release wiper arm -2- from adjusting tool and re- secure with locking bolt -3-. - Check set value against table. If necessary, re- peat setting and checking procedure until spe-ci- fied value is achieved. - Remove adjusting tool and fit wiper blade. - Check that windscreen wiper system operates without juddering. 20
  • 15. Self-diagnosis: interrogate fault memory with fault reader V.A.G 1551 Connecting V.A.G 1551: - Apply the handbrake. - Move selector lever to position "P" or "N" on mod- els with automatic gearbox. - Remove cover from additional relay carrier I on left of plenum chamber. - Ensure that ignition is switched off, then connect black connector to black diagnostic connection. V.A.G Indicated on display: 1) appears alternately Note: If the display remains blank: => Fault Reader Operating Instructions - Connect white connector to white or brown dia- gnostic connection (blue connector not required). 21 - Switch on printer with PRINT key (indicator lamp in key illuminates). - Enter "1" to select "Rapid data transfer". Interrogating fault memory - Start engine and run at idling speed. - Briefly press brake pedal. - Enter "00" for address word "Automatic test se- quence" and confirm entry with Q key. The V.A.G 1551 transmits all known address words in se- quence. If a control unit answers with its identification, the number of faults stored or "No fault detected" ap- pears on the display. Any system faults stored will be displayed in se- quence and printed out. The V.A.G 1551 will then transmit the next address word. V.A.G The automatic test sequence has ended when the following appears on the display: 1) appears alternately - Switch ignition off. If faults have been stored, they must be rectified. The fault print-out is required for carrying out the re- pair work. Notes: ♦ It may be necessary to leave V.A.G 1551 con- nected in order to carry out the exhaust emis- sion test. 22
  • 16. ♦ On vehicles with 5-cyl. 2V engine (engine code "AAR") it is also necessary to interrogate the fault memory for engine electronics in "Flash code output" mode. Interrogating fault memory for engine electronics (engine code "AAR") - Start engine and run at idling speed. - Press key "2" for "Flash code output". - Press ⇒ key. Any faults (flash codes) stored in the fully-electronic ignition control unit will appear in sequence on the display and on the print-out. Flash code: 4444 No fault detected If no faults have been stored in the memory, this message will appear on the display: Flash code: 0000 Output ends After the last fault or "Flash code 4444 No faults re- cognised" has been displayed, this message will ap- pear on the display: Notes: ♦ With the printer switched on, V.A.G 1551 will now advance to the next step and interrogate the fault memory of the KE III Jetronic control unit. ♦ The idling speed will be increased while the fault memory of the KE III Jetronic control unit is in- terrogated. Any faults (flash codes) stored in the KE III Jetronic control unit will appear in sequence on the display and on the print-out. 23 Flash code: 4444 No fault detected If no faults have been stored in the memory, this message will appear on the display: Flash code: 0000 Output ends After the last fault or "Flash code 4444 No faults re- cognised" has been displayed, this message will ap- pear on the display: - Switch ignition off. If faults have been stored, they must be rectified. The fault print-out is required for carrying out the re- pair work. Service interval display: reset Audi A6 / S6 The service interval display must be reset (using fault reader V.A.G 1551) after each Oil Change Ser- vice or Inspection Service. When a service is due, the type of service required will be indicated by a flashing message on the trip recorder display when the ignition is switched on. The message will continue to flash for up to 60 seconds after the engine has been started. Display Type of service due OIL Oil Change Service In 1 Inspection Service In 2 Inspection Service with additional jobs The service due will be indicated either 1,000 km or 10 days in advance. 24
  • 17. - Connect V.A.G 1551 => Page 23. - Switch the ignition on. V.A.G Indicated on display: 1) appears alternately - Enter "1" to select "Rapid data transfer". Rapid data transfer HELP Enter address word XX Indicated on display - Enter "17" for address word "Dash panel insert" and confirm entry with Q key. 4A1919033HG C4-INSTRUMENT CLUSTER D20 ⇒ Coding 00040 WSC 12345 If following display appears (example): - Press ⇒ key to continue. - Enter "10" to select the "Adaption" function and confirm with the Q key. Adaption Q Enter channel no. XX Indicated on display - Enter the required adaption channel according to the following table. 25 Type of service due service due to be can- celled Adap- tion channel Input value OIL OIL 05 00015 In 1 OIL In 1 (dis- tance) In 1 (time) 05 06 07 00015 00030 00036 In 2 OIL In 1 (dis- tance) In 1 (time) In 2 05 06 07 08 00015 00030 00036 00073 Resetting SID in adaption channel 05 (OIL): - Enter "05" to select "Adaption channel 05" and confirm entry with Q key. Channel 5 Adaption 1 ⇒ (-1 3-L Indicated on display: The figure displayed indicates the number of kilo- metres remaining until the OIL Service is due (e.g. "1" for 1,000 km). - Press ⇒ key. Channel 5 Adaption 1 Q Enter adaption value XXXXX Indicated on display - Enter "00015" for "15,000 km until next OIL Ser- vice" and confirm with Q key. 26
  • 18. Note: Always enter the distance in kilometres even for vehicles that are calibrated for miles. Channel 5 Adaption 15 Q (-1 3-L Indicated on display - Confirm entry with Q key. Channel 5 Adaption 15 Q Store changed value? Indicated on display - Confirm entry with Q key. Channel 5 Adaption 15 ⇒ Changed value is stored Indicated on display - By pressing the ⇒ key complete resetting pro- cedure for SID in "adaption channel 05". Resetting SID in adaption channel 06 (In 1): - Enter "06" to select "Adaption channel 06" and confirm entry with Q key. Channel 6 Adaption 1 ⇒ (-1 3-L Indicated on display: The figure displayed indicates the number of kilo- metres remaining until the next Inspection Service 1 is due (e.g. 1 for 1,000 km). - Press ⇒ key. Channel 6 Adaption 1 Q Enter adaption value XXXXX Indicated on display - Enter "00030" for "30,000 km until next Inspection Service 1" and confirm with Q key. Note: Always enter the distance in kilometres even for vehicles that are calibrated for miles. 27 Channel 6 Adaption 30 Q (-1 3-L Indicated on display - Confirm entry with Q key. Channel 6 Adaption 30 Q Store changed value? Indicated on display - Confirm entry with Q key. Channel 6 Adaption 30 ⇒ Changed value is stored Indicated on display - By pressing the ⇒ key complete resetting pro- cedure for SID in "adaption channel 06". Resetting SID in adaption channel 07 (In 1): - Enter "07" to select "Adaption channel 07" and confirm entry with Q key. Channel 7 Adaption 1 ⇒ (-1 3-L Indicated on display: The display will show the number of days remaining before Inspection Service 1 is due. In this example, 1 = 10 days). - Press ⇒ key. Channel 7 Adaption 1 Q Enter adaption value XXXXX Indicated on display - Enter "0036" for "365 days until next Inspection Service 1" and confirm with Q key. Channel 7 Adaption 36 Q (-1 3-L Indicated on display - Confirm entry with Q key. Channel 7 Adaption 36 Q Store changed value? Indicated on display - Confirm entry with Q key. Channel 7 Adaption 36 ⇒ Changed value is stored Indicated on display 28
  • 19. - By pressing the ⇒ key complete resetting pro- cedure for SID in "adaption channel 07". Resetting SID in adaption channel 08 (In 2): - Enter "08" to select "Adaption channel 08" and confirm entry with Q key. Channel 8 Adaption 12 ⇒ (-1 3-L Indicated on display: The display will show the number of days remaining before Inspection Service 2 is due. In this example, 12 = 120 days). - Press ⇒ key. Channel 8 Adaption 12 Q Enter adaption value XXXXX Indicated on display - Enter "00073" for "730 days until next Inspection Service 2" and confirm with Q key. Channel 8 Adaption 73 Q (-1 3-L Indicated on display - Confirm entry with Q key. Channel 8 Adaption 73 Q Store changed value? Indicated on display - Confirm entry with Q key. Channel 8 Adaption 73 ⇒ Changed value is stored Indicated on display - By pressing the ⇒ key complete resetting pro- cedure for SID in "adaption channel 08". 29 Door arresters and lock cylinders: lubric- ate - Only grease the door arresters at the points shown in the illustration -arrows-. - Lubricant: "G 052 778 A2" - Lubricate the lock cylinder. - Lubricant: "G 052 778 A2" 30
  • 20. Sun roof: check function, clean guide rails and spray with lubricating spray - Check the sun roof for leaks. - Clean the guide rails. - Spray the guide rails. - Lubricant: "G 052 778 A2" - Check function of sun roof. Removing plenum chamber cover - Pull plenum chamber cover - 1 - out of retaining clips -arrows- and lift up at the front. - Detach plenum chamber cover to front. Note: When installing the plenum chamber cover, insert it carefully under the water deflector on the bottom edge of the windscreen to prevent water from enter- ing the dust and pollen filter or the heating system. 31 Battery: check electrolyte level and top up with distilled water if necessary Fitting location of battery: ♦ Vehicles without jump lead connection in engine compartment: below plenum chamber cover on right ♦ Vehicles with jump lead connection in engine compartment: below rear seat bench on right ♦ Vehicles with auxiliary heater: additional (2nd) battery on left of luggage com- partment behind cover in side trim Vehicles without jump lead connection in engine compartment: - Remove plenum chamber cover => Page 31. 32
  • 21. Vehicles with jump lead connection in engine compartment: - To remove rear seat bench, unscrew cross-head screws on left and right. - Raise rear seat bench slightly and take out to- wards the front. Additional (2nd) battery on vehicles with auxili- ary heater: - Open cover in side trim on left of luggage com- partment. All models: - Checking electrolyte level: - The electrolyte level should be between the MIN and MAX markings. - If necessary, top up battery cells to max. mark with distilled water. Notes: ♦ For batteries with clearly visible min and max mark, the electrolyte level can be checked visu- ally from the outside of the battery. ♦ If the electrolyte level is not visible from the out- side unscrew the battery caps. ♦ The electrolyte level must align with the marking inside the battery - plastic web - . This corres- ponds to the outer max marking. 33 Removing engine cover - Loosen bolts and nuts -arrows- and take off en- gine cover. 4-cyl. 5V engines V6 - 2V-engines: 34
  • 22. V6 - 5V engines: V8-engines > 1994: 35 V8-engines 1995 > : 4-cyl. TDI engines 36
  • 23. 5-cyl. TDI engines 37 Engine (from above and below) and en- gine compartment: visual check for leaks and damage Perform visual check as follows: - If necessary, remove engine cover => Page 34. - Check engine and engine compartment for leaks and damage. - Check the pipes, hoses and connections of the following systems for leaks, chafing, porosity and brittleness. - Fuel system - Cooling and heating system - Brake system - Perform a visual check of the same areas from below with the vehicle raised on a lifting platform and the noise insulation removed. Important Faults found must be rectified (repair meas- ure). 38
  • 24. Windscreen / headlight washer system: top up fluid - Fill container in engine compartment to the top with washer fluid. On Avant models, the container for the rear window washer is at the back of the luggage compartment, behind the side trim on the right. - To fill container, swivel filler pipe on container in- to luggage compartment -arrow-. Note: The washer fluid must always contain a pH-neutral screen cleaning fluid (antifreeze in winter). Intensive washer system The fluid container for the intensive washer system is on the right of the plenum chamber, next to the cover. - Fill container right up to the top with intensive cleaning fluid "D 005 100 10". Note: To avoid damaging the paintwork and causing discol- ouring, do not use any other intensive cleaning fluid than "D 005 100 10". 39 Cooling system: check antifreeze and top up coolant if necessary Notes: ♦ The cooling system is filled all year round with a mixture of water and antifreeze/corrosion pro- tection agent. ♦ Coolant additive "G 011 A8 C" (green) is used up to vehicle identification no. 4AVN 002 872. ♦ Coolant additive "G 012 A8 D" (red) is used as of vehicle identification no. 4AVN 002 873. Important The two different coolant additives "G 011 A8 C" (green) and "G 012 A8 D" (red) must not be mixed together. Otherwise, this can result in serious damage to the engine. ♦ If the fluid in the expansion tank is brown, this means G 012 A8 D has been mixed with another type of coolant. In this case, flush out the cool- ing system and fill with fresh coolant. To flush the system, fill it with clean water and run the engine for about 2 minutes. This should remove as much of the old coolant as possible. 40
  • 25. ♦ "G 011 A8 C" and coolant additives "conforming to TL VW 774 C" or "G 012 A8 D" and coolant ad- ditives "conforming to TL VW 774 D" prevent frost and corrosion damage, scaling and also raise the boiling point of the coolant. For these reasons the cooling system must be filled all year round with the correct anti freeze and anti corrosion additive. Checking coolant level and topping up if neces- sary - Check coolant level on expansion tank while the engine is cold. ♦ Coolant level between MIN and MAX marks - If coolant level is too low, add required amount according to mixture ratio. Mixture ratio Frost protec- tion to Coolant additive Water - 25 °C approx. 40 % 1) approx. 60 % - 35 °C approx. 50 % approx. 50 % - 40 °C approx. 60 % approx. 40 % 1) For V8 engines 40 % concentration of coolant additive is not sufficient to give adequate protection against corrosion. Notes: 41 ♦ Because of its high boiling point, the coolant im- proves engine reliability under heavy loads, par- ticularly in countries with tropical climates. ♦ Protection against frost must be assured to about - 25 °C (for V8 engines and in countries with an arctic climate to about -35 °C). ♦ The coolant concentration must not be reduced by adding water even in warmer seasons and in warmer countries. The proportion of anti-freeze must be at least 40 % (50 % for V8 engines). ♦ If greater frost protection is required in very cold climates, the amount of "G 011 A8 C" or "G 012 A8 D" can be increased, but only up to 60 % (or 54 % for V8 engines). This gives frost protection to around -40 °C), as otherwise frost protection is reduced again and cooling effectiveness is also reduced. Checking antifreeze and topping up coolant ad- ditive if necessary - If the degree of frost protection is too low, drain off the required quantity as specified in the frost protection table (=> Page 43) and add coolant ad- ditive: - Up to vehicle identification number 4AVN 002 872 "G 011 A8 C" or coolant additive "according to TL VW 774 C" - From vehicle identification number 4AVN 002 873 "G 012 A8 D" or coolant additive "according to TL VW 774 D" 42
  • 26. Note: Observe environmental requirements for disposal. Frost protection table Frost protec- tion to °C Required quantity in litres Actual value Spe- cified value 4-/5- cyl. petrol en- gine 4-/5- cyl. diesel en- gine 5-cyl. 4V 6-cyl. 8-cyl. 0 -25 3.0 3.5 4.0 5.0 - -35 3.5 4.0 5.0 6.0 6.0 -5 -25 2.5 3.0 3.5 4.5 - -35 3.5 3.5 4.5 5.5 5.5 -10 -25 2.0 2.0 3.0 3.5 - -35 3.0 3.0 4.0 4.5 4.5 -15 -25 1.5 1.5 2.0 2.5 - -35 2.5 2.0 3.0 3.5 3.5 -20 -25 1.0 1.0 1.5 1.5 - -35 2.5 1.5 2.0 2.5 2.5 -25 -35 2.0 1.0 1.5 1.5 1.5 -30 -35 1.0 0.5 1.0 1.0 1.0 -35 -40 0.5 0.5 0.5 0.5 0.5 - Check coolant additive concentration after test drive. 43 Coolant G11: Change (V8 petrol engines only) To prevent corrosion damage, the coolant must be changed at regular intervals in vehicles with V8 pet- rol engines up to vehicle identification no. 4AVN 002 872 if coolant additive "G 011 A8 C" (green) has been used. - Draining and filling cooling system => 8-cylinder Engine, Mechanical Components; Re- pair group 19; Removing and installing parts of the cooling system; Draining and filling system with coolant Notes: ♦ Observe environmental requirements for dispos- al. ♦ When changing the coolant it is also possible to use coolant additive "G 012 A8 D" (red) instead of coolant additive "G 011 A8 C" (green). If switching to "G 012 A8 D", always follow the rel- evant instructions: => 8-cylinder Engine, Mechanical Components; Re- pair group 19; Removing and installing parts of the cooling system; Draining and filling system with coolant ♦ After switching to coolant additive "G 012 A8 D" (red) it is no longer necessary to change the coolant (system is then filled for life). 44
  • 27. Air cleaner: clean housing and replace filter element Engines without mixture control unit on air filter cover: - Loosen hose clamp on air intake pipe/hose and detach pipe/hose. - Release clips -arrows- around air cleaner housing and press cover to the side. - If necessary, unplug connector for air mass meter/air flow meter. - Remove old filter element. Note: Observe environmental requirements for disposal. - Clean filter housing and install new filter element. Note: On vehicles with V6 - 5V-petrol engines renew the spark plugs and fit the spark plug connectors before refitting the top section of the air cleaner. 45 Engines with mixture control unit on air filter cover: - Remove air intake hose above mixture control unit. - Release clips around air cleaner housing -arrows-. - Pull out mixture control unit with upper section of air cleaner housing from above. - Remove old filter element. Note: Observe environmental requirements for disposal. - Clean filter housing and install new filter element. Audi S4 (V8): - Unbolt upper section of air cleaner housing. - Remove old filter element. Note: Observe environmental requirements for disposal. - Clean filter housing and install new filter element. 46
  • 28. Spark plugs: replace Special tools required ♦ Spark plug socket, A/F 20.8 (4-cyl. 2V and 5-cyl. 2V engines) ♦ Spark plug socket 3122 B (4-cyl. 4V, 4-cyl. 5V, 5-cyl. 4V engines, 6- and 8- cylinder engines) Notes: ♦ The spark plugs must be renewed every 15,000 km if the vehicle is run on leaded fuel. ♦ Spark plug designation => "Exhaust Emission Test" binder ♦ Observe environmental requirements for dispos- al. 4-cyl. 2V and 5-cyl. 2V engines: - With ignition switched off, unplug connectors from spark plugs. - Remove spark plugs with spark plug socket. - Screw in new spark plugs. - Check ignition cables and spark plug connectors are correctly seated. Tightening torque Nm Spark plugs in cylinder head 30 47 4-cyl. 4V engines: - With ignition switched off, unplug connectors -ar- rows- from spark plugs. Note: Use the special puller fitted on the spark plug con- nector of cylinder 1 to detach all the spark plug con- nectors. - Remove spark plugs using spark plug socket 3122 B. - Screw in new spark plugs. - Check ignition cables and spark plug connectors are correctly seated. Tightening torque Nm Spark plugs in cylinder head 30 4-cyl. 5V engines: - Remove engine cover => Page 34. 48
  • 29. - With ignition switched off, unscrew and unclip connector and earth wire from ignition coil with output stage -arrows-. - Remove spark plugs using spark plug socket 3122 B. - Fit spark plugs and ignition coil with output stage. - Check ignition cables and spark plug connectors are correctly seated. Tightening torques Nm Spark plugs in cylinder head 30 Ignition coil with output stage to cyl- inder head cover 10 49 5-cyl. 4V engines (turbo): - Unscrew mountings of ignition coil carrier -arrows- and pull carrier evenly off towards the top. - Remove spark plugs using spark plug socket 3122 B. - Screw in new spark plugs. - Install ignition coil carrier; replace gasket if dam- aged. Tightening torques Nm Spark plugs in cylinder head 30 Ignition coil carrier to cylinder head cover 10 50
  • 30. V6 - 2V engines: - If necessary remove air intake pipe -1- between air cleaner and throttle valve unit. - Remove engine cover => Page 34. - With ignition switched off, unplug connectors -ar- rows- from spark plugs. - Remove spark plugs using spark plug socket 3122 B. - Screw in new spark plugs. - Check ignition cables and spark plug connectors are correctly seated. Tightening torque Nm Spark plugs in cylinder head 30 V6 - 5V engines: - Remove air intake pipe between air cleaner and throttle valve unit. - To unscrew rear left spark plug, remove coolant expansion tank and connected hoses. - Remove engine cover => Page 34. 51 - Detach spark plug connector -arrows-. - Remove spark plugs using spark plug socket 3122 B. - Screw in new spark plugs. - Check ignition cables and spark plug connectors are correctly seated. Tightening torque Nm Spark plugs in cylinder head 30 V8 engines (206 and 213 kW): - Remove air intake pipe between air cleaner and throttle valve unit. - Remove engine covers => Page 40. - With ignition switched off, unplug connectors from spark plugs. Note: Use the special puller -arrow- fitted on the spark plug connector of cylinder 1 to detach all the spark plug connectors. - Remove spark plugs using spark plug socket 3122 B. - Screw in new spark plugs. - Check ignition cables and spark plug connectors are correctly seated. Tightening torque Nm Spark plugs in cylinder head 30 V8 engines (240 kW): 52
  • 31. - Remove air intake pipe between air cleaner and throttle valve unit. - Remove engine covers => Page 40. - With the ignition switched off, pull the retainer clips for the ignition coil connectors upwards and unplug the connectors. - Unscrew ignition coils -arrows-. - Remove spark plugs using spark plug socket 3122 B. - Install new spark plugs using spark plug socket. - Install ignition coils. Replace seals if damaged. Tightening torques Nm Spark plugs in cylinder head 30 Ignition coils to cylinder head cover 10 53 Hydraulic system: check for leaks, check fluid level and top up hydraulic fluid if necessary Note: In the case of vehicles with self-levelling suspension, the vehicle must be in its unladen state when check- ing the fluid level. • Cold fluid: - Do not run engine and set front wheels to straight-ahead position. • Fluid at operating temperature (from approx. 50 °C): - Run engine and set front wheels to straight - ahead position. - Unscrew filler cap -arrow- with dipstick. - Wipe dipstick with a clean cloth. - Screw in cap hand-tight and unscrew again. 54
  • 32. - Check fluid level: • Cold fluid: - Level must be around MIN. mark (up to 2 mm above or below mark). • Fluid at operating temperature (from approx. 50 °C): - Level must be between MIN. and MAX. mark. Notes: ♦ The definitive fluid level is the one measured after screwing in the cap. ♦ Fluid must be drawn off if the level is above the specified range. Important If the fluid level is below the range specified, the hydraulic system must be checked for leaks (repair measure). It is then not sufficient to merely top up the fluid. - If there are no leaks in the hydraulic system, top up with "G 002 000". - Screw in cap hand-tight. 55 Fuel filter: replace (diesel and TDI en- gines) Notes: ♦ Please ensure that no diesel fuel contacts coolant hoses. If necessary, clean hoses imme- diately. ♦ Observe environmental requirements for dispos- al. 4-cyl. TDI engines: - Loosen hose clamps on fuel hoses -1- and -2- and disconnect both fuel hoses. - Loosen nut -arrow- on filter bracket and pull filter out of bracket without disconnecting the two fuel hoses. - Using a 17 mm open-ended spanner, counterhold upper part of fuel filter at flats on boss for bleed screw. Unscrew filter using strap wrench if ne- cessary -arrow-. Important Do not use pliers to hold the fuel filter. This can damage the head of the filter and cause leaks in the fuel system. - Unscrew filter from upper part of fuel filter. - coat new rubber seal lightly with diesel fuel. - Fill new filter with clean diesel. This will enable the engine to start more quickly. 56
  • 33. - Screw filter onto upper part of filter flange (hand- tight). - Push plastic insert onto new filter. - Insert fuel filter into bracket and secure with clamping nut -arrow-. - Connect fuel hoses -1- and -2- and secure with new hose clamps (use correct type - same as ori- ginal equipment). => Parts List - Start engine and check fuel system for leaks (visual check). Tightening torque Nm Clamping nut on filter bracket 10 5-cyl. diesel and TDI engines: - Unplug connector for water level sender. - Hold filter in place using a strap wrench, unscrew banjo bolt -1- and remove filter. Note: Do not turn filter. - Moisten new seal and new rubber seal with dies- el. - Transfer water level sender (if fitted) with new O- ring onto replacement filter. - Fill new filter with clean diesel. This will enable the engine to start more quickly. - Fit a new O-ring and tighten banjo bolt hand-tight. 57 - Start engine and check fuel system for leaks (visual check). - Press the accelerator pedal several times - with the engine running at idling speed the fuel should flow through the transparent pipe with no bubbles. Fuel filter: drain off water (Diesel and TDI engines) Notes: ♦ Please ensure that no diesel fuel contacts coolant hoses. If necessary, clean hoses imme- diately. ♦ Observe environmental requirements for dispos- al. 4-cyl. TDI engines: - Release hose clamps on fuel hoses -1- and -2- and disconnect both fuel hoses. - Loosen nut -arrow- on filter bracket and pull filter out of bracket without disconnecting the two fuel hoses. 58
  • 34. - Open water drain plug and drain approx. 0.1 litre of fluid into a drip tray. - Close water drain screw. - Coat rubber seal on fuel filter lightly with diesel fuel. - Insert fuel filter into bracket and secure with clamping nut -arrow-. - Connect fuel hoses -1- and -2- and secure with new hose clamps (use correct type - same as ori- ginal equipment). => Parts List - Start engine and check fuel system for leaks (visual check). Tightening torque Nm Clamping nut to filter bracket 10 59 5-cyl. diesel and TDI engines: - Release vent screw -2-. - Fit hose onto water drain screw or breather valve - 3-. Note: Vehicles > 1994 with engine code AAT and ABP have a water drain valve instead of a water drain screw. - Unscrew water drain screw or press drain valve upwards and drain off about 0.1 litre of fluid. - Tighten water drain screw or release drain valve and tighten vent screw. - Start engine and check fuel system for leaks (visual check). - Press the accelerator pedal several times - with the engine running at idling speed the fuel should flow through the transparent pipe with no bubbles. 60
  • 35. Dust and pollen filter: replace The filter is located below the plenum chamber cov- er on the right. Vehicle Page Audi 100 > 1992 without air conditioner with M-Nr. 2V1 61 Audi 100 1993 > 1994 without air condi- tioner 61 Audi A6 1995 > without air conditioner 61 Audi A6 1995 > with air conditioner 62 Audi 100 > 1994 without air conditioner: - Remove plenum chamber cover => Page 31. - Unscrew both nuts -A-. - Turn filter cartridge and take out of bracket. Note: Observe environmental requirements for disposal. - Install new filter element. - Before fitting plenum chamber cover, check plen- um chamber and water drain valves for dirt => Page 63. Audi A6 1995 > without air conditioner: - Remove plenum chamber cover => Page 31. - Depending on the size of the battery, either loosen battery retainer and push battery towards wing panel or remove battery completely. 61 - Push clamp -A- up and remove dust and pollen fil- ter -B- from filter holder. Note: Observe environmental requirements for disposal. - Install new filter element. - Before fitting plenum chamber cover, check plen- um chamber and water drain valves for dirt => Page 63. Audi A6 1995 > with air conditioner: - Remove plenum chamber cover => Page 31. - Unscrew the three bolts -A-. - Remove cover -B- and pull dust and pollen filter - C- out of evaporator. Note: Observe environmental requirements for disposal. - Before installing dust and pollen filter, check evaporator for dirt and clean if necessary. - Insert dust and pollen filter (ensure that filter is the right way round). - Arrow on filter element points towards evaporat- or. - Before fitting plenum chamber cover, check plen- um chamber and water drain valves for dirt => Page 63. 62
  • 36. Plenum chamber and water drain valves: check for dirt and clean if neces- sary - Remove plenum chamber cover => Page 31. - Check plenum chamber for dirt (leaves, etc.) and clean as necessary. - Check that water drain valves are functioning properly, and clean and replace as necessary. Note: Ensure that water drain valves close properly and are not blocked by wax or underseal. - Observe note on installing plenum chamber cover => Page 31. 63 Noise insulation: remove On vehicles with diesel and TDI engines the noise in- sulation consists of two parts. - Turn quick - release screws - arrows - in an anti - clockwise direction. - Pull front noise insulation off bumper towards rear of vehicle and remove. - Pull rear noise insulation (on diesel and TDI en- gines only) towards rear of vehicle and remove. Note: When installing ensure that the noise insulation is pushed in over the bumper cover at the front. 64
  • 37. V-belt: check for damage and check ten- sion; adjust tension if necessary - Check condition of V-belts along entire length of belt: - Cracks, fractured core, cross-sectional breaks - Layer separation (base, cord strands) - Base break-up - Fraying of cord strands - Wear on sides of belt (material worn down, sides of belt frayed, surface cracking or sides of belt hardened - indicated by smooth, shiny sur- face) - Traces of oil and grease Important Faults found must be rectified (repair meas- ure). - Check tension of V-belts: - Press in the ribbed belt firmly with the thumb at a point half-way between the two pulleys which are farthest apart. The amount of yield should be as follows: 65 V-belt for alternator Belt yield (max) - New V-belt 2 mm - Used V-belt 5 mm V-belt for PAS vane pump - Petrol engines 10 mm - TDI engines 5 mm V-belt for air conditioner compressor - All models 5 mm V-belts: tensioning Note: With the 4-cyl. 5V-engine it is not possible to adjust the tension of the V-belt for the coolant pump. Special tools required ♦ V.A.G 1410 Torque wrench ♦ Ring spanner attachment V.A.G 1410/2 (22 mm A/F) • V-belt for alternator 66
  • 38. - loosen all bolts securing alternator and tensioning bar -A- at least one turn. - Loosen clamping bolt for tensioner nut -B-. - Using torque wrench V.A.G 1410 and ring span- ner attachment V.A.G 1410/2 (22 mm A/F), apply the following torque to the tensioner nut: - Used V-belt:4 Nm - New V-belt: 8 Nm - Maintain this torque on tensioning bolt, and tight- en clamping bolt to 35 Nm. Tightening torques Nm Clamping bolt for tensioner nut to ten- sioning bar 35 Tensioning bar to lifting eye 20 Alternator to bottom mounting 35 Note: If the V-belt has been replaced: - Start engine and run at idling speed for 5 minutes. - Switch off the engine and re-adjust the belt ten- sion as described above. - Apply a torque of 8 Nm to tensioner nut. • V-belt for PAS vane pump - Remove noise insulation => Page 64. 67 - Loosen bolts 2 ... 6. - Adjust belt tension with tensioner nut -1-. - The amount of yield should be as follows: - Petrol engines:10 mm - TDI engines: 5 mm - Tighten securing bolts on vane pump. Tightening torques Nm Vane pump to bracket 25 Vane pump to tensioning bar 25 • V-belt for air conditioner compressor - Remove noise insulation => Page 64. - Unscrew the 4 nuts -1-. - Detach hub -2- from belt pulley. - Take off front section of belt pulley -3-. Notes: ♦ Belt tension is adjusted by adding or taking out shims -5- between front section -3- and rear sec- tion -4- of belt pulley. ♦ To reduce tension, add shims between two sec- tions of belt pulley. ♦ To increase tension, remove shims between two sections of belt pulley. 68
  • 39. - Place remaining shims between hub -2- and the front section of belt pulley -3-. - Loosely bolt together the two sections of the belt pulley. - Tighten the bolts securing the two sections of the pulley in stages while turning the crankshaft. - As the bolts are tightened, the V - belt should gradually move outwards until seated on the contact surface. - Tighten nuts to 25 Nm. - The amount of yield should be as follows: - Used V-belt:5 mm - New V-belt: 2 mm - Start engine and check belt running. - Check the belt tension again and re-adjust if ne- cessary. 69 V-belt (not ribbed belt) for alternator: re- place Special tools required ♦ V.A.G 1410 Torque wrench ♦ Ring spanner attachment V.A.G 1410/2 (22 mm A/F) 4-cyl. petrol engines - Remove noise insulation => Page 64. - Remove V-belt for air conditioner compressor: - Unscrew the 4 nuts -1-. - Detach hub -2- from belt pulley. - Take off front section of belt pulley -3-. - Remove V-belt. 70
  • 40. - Remove V-belt for PAS vane pump: - Loosen bolts 2 ... 6. - Remove V-belt. - Remove V-belt for alternator: - loosen all bolts securing alternator and tensioning bar -A- at least one turn. - Loosen clamping bolt for tensioner nut -B-. - Fit new V-belt for alternator. - Re-install the other V-belts. - Tension the V-belts => Pages 68. 71 Ribbed belt: check for damage - Check condition of ribbed belts along entire length of belt: - Cracks, fractured core, cross-sectional breaks - Layer separation (base, cord strands) - Base break-up - Fraying of cord strands - Wear on sides of belt (material worn down, sides of belt frayed, surface cracking) - Traces of oil and grease Important Faults found must be rectified (repair meas- ure). 72
  • 41. Ribbed belt: check tension; adjust if ne- cessary Special tools required ♦ V.A.G 1410 Torque wrench ♦ Ring spanner attachment V.A.G 1410/2 (22 mm A/F) - Press in the ribbed belt firmly with the thumb at a point half-way between the pulleys. - The belt should yield 5 mm - Loosen the alternator securing bolt -1- and clamp- ing bolt -2- at least one turn. - Using torque wrench V.A.G 1410 and ring span- ner attachment V.A.G 1410/2 (22 mm A/F), apply a torque of 6 Nm to the tensioner nut -3-: - Maintain this torque on the tensioning bolt, and tighten clamping bolt to 25 Nm. Tightening torques Nm Clamping bolt for tensioner nut to ten- sioning bar 25 Alternator to bottom mounting 25 73 V-belt and ribbed belt: replace (4-cyl. 5V engines) Special tools required ♦ Mandrel 3204 Removing • Ribbed belt for air conditioner compressor - Unbolt torque reaction support from engine and cross member -arrows-. - Loosen bolts -arrows- of tensioner for ribbed belt, slacken belt and remove. • Ribbed belt for PAS vane pump and alternator 74
  • 42. - Remove ribbed belt for air conditioner com- pressor => Page 74. - Loosen ribbed belt for hydraulic pump and altern- ator, secure tensioner for ribbed belt using man- drel 3204 if necessary -arrows-. - Remove ribbed belt between hydraulic pump and alternator at alternator. • V-belt for coolant pump - Unscrew pulley for coolant pump. To prevent pul- leys from turning, insert a pin -arrow- in the vane pump pulley. - Remove V-belt. Installing Installation is carried out in the reverse order; note the following: - Fit ribbed belt for PAS vane pump and alternator. - Fit V-belt and assemble two sections of pulley on coolant pump without tightening bolts. - Tighten the bolts securing the two sections of the pulley in stages while turning the coolant pump. - As the bolts are tightened, the V - belt should gradually move outwards until seated on the contact surface. - Tighten bolts to 25 Nm. 75 Note: It is not possible to adjust the tension of the V-belt for the coolant pump. - Check that ribbed belt is properly seated. - Turn ribbed belt tensioner in direction of arrow. - Remove mandrel 3204 if necessary. - Fit ribbed belt for A/C compressor. - Apply torque wrench to hexagon on tensioning roller and tension with a torque of 25 Nm. - At the same time, tighten bolts -A- to 20 Nm. - Start engine and check belt running. - Check again to ensure that the bolts for the coolant pump pulley are tightened to the correct torque. 76
  • 43. Ribbed belt: replace (V6 engines) Special tools required ♦ Mandrel 3204 - Remove engine cover => Page 34. - Remove cover for ribbed belt -arrows-. 77 Vehicles > 1991: - To slacken ribbed belt, turn tensioner in direction of arrow using ring spanner (15 mm A/F). - Secure tensioner by inserting mandrel 3204. - Remove ribbed belt. - Fit new ribbed belt onto drive pulley and idler wheel first, and then push it over the tensioner. Routing of belt - A1 - without air conditioner - A2 - with air conditioner - Take out mandrel 3204 and release tensioner for ribbed belt. - Start engine and check belt running. 78
  • 44. Vehicles 1992 >: - To slacken ribbed belt, turn tensioner in direction of arrow using Allen key (10 mm A/F). - Insert mandrel 3204 into holes -A- and -B- to stop tensioner from turning. - Remove ribbed belt. - Fit new ribbed belt onto drive pulley and idler wheel first, and then push it over the tensioner. Routing of belt on vehicles 1992 > 1994 - B1 - without air conditioner - B2 - with air conditioner 79 Routing of belt on vehicles 1995 > - C1 - without air conditioner - C2 - with air conditioner - Take out mandrel 3204 and release tensioner for ribbed belt. - Start engine and check belt running. 80
  • 45. Toothed belt for camshaft drive: check for damage and measure toothed belt width (4-cyl. TDI engines) - Release 2 clamps on the upper toothed belt cover and pull upper end of cover forwards. - Check condition of toothed belt: - Cracks, cross-sectional fractures - Layer separation (base, cord strands) - Base break-up - Fraying of cord strands - Surface cracks (plastic outer layer) - Traces of oil and grease Important Faults found must be rectified (repair meas- ure). - Measure width of toothed belt -a-. - Wear limit = 22 mm Important The toothed belt must be replaced if the belt width is less than 22 mm (repair measure). 81 Toothed belt for camshaft drive: check for damage and check tension (5-cylin- der diesel and TDI engines) - Remove upper toothed belt cover. - Check condition of toothed belt: - Cracks, cross-sectional fractures - Layer separation (base, cord strands) - Base break-up - Fraying of cord strands - Surface cracks (plastic outer layer) - Traces of oil and grease Important Faults found must be rectified (repair meas- ure). Vehicles > 1994: - Check that toothed belt runs centrally on cam- shaft sprocket. Note: If the toothed belt runs on one side of the sprocket, this means that the lower idler wheel is not pressed in straight and should be replaced (repair measure). - Check tension of toothed belt: Special tools required ♦ V-belt and toothed belt test unit VW 210 82
  • 46. - Press in toothed belt firmly by hand between camshaft sprocket and injection pump sprocket to equalise tension. - Measure tension of toothed belt using tester VW 210. - Specification: on scale 12 ... 13 - Adjust toothed belt tension (repair measure) if the reading does not match the specification (too high or too low): => 5-cyl. Diesel Engine (2.4 ltr Engine), Mechanical Components; Repair group 13; Dismantling and as- sembling engine; Removing and installing toothed belt for camshaft => 5-cyl. Diesel Engine (2.5 ltr Engine), Mechanical Components; Repair group 13; Dismantling and as- sembling engine; Removing and installing toothed belt for camshaft Vehicles 1995 >: - Check tension of toothed belt: 83 - The two arrows must be aligned (max. distance 3 mm) - If the markings are not opposite each other adjust the tension of the toothed belt: => 5-cyl. Diesel Engine (2.5 ltr Engine), Mechanical Components; Repair group 13; Dismantling and as- sembling engine; Removing and installing toothed belt for camshaft 84
  • 47. Toothed belt for injection pump: check for damage and check tension (5-cyl. TDI engines), tension toothed belt Special tools required ♦ Tensioner 3303 Vehicles > 1994: - Remove rear toothed belt cover. Vehicles 1995 >: - Remove engine cover => Page 40. All models: - Check condition of toothed belt: - Cracks, cross-sectional fractures - Layer separation (base, cord strands) - Base break-up - Fraying of cord strands - Surface cracks (plastic outer layer) - Traces of oil and grease Important Faults found must be rectified (repair meas- ure). 85 - Check tension of toothed belt for injection pump. Vehicles 1995 >: - Unscrew nut -A- on rear toothed belt guard for in- jection pump drive. - Push toothed belt guard and sleeve -B- to rear. All models: - Hook in spring of tensioner 3303. Note: In order to attach the tensioner on vehicles 1995> without removing the stud, first file out a section of the tensioner, as shown in the illustration (shaded area). 86
  • 48. - With tensioner 3303 -Item 1- hooked in position, loosen nut -2- of tensioning roller. - Move the tensioning roller by hand to check that it moves easily; free the roller if necessary. Note: When the tensioning roller is released, the spring of the tensioner automatically sets the belt to the cor- rect tension. - Check gap -A- at stop for tensioning roller. Important If gap A = 0 mm (tensioning roller lever against stop) the toothed belt must be replaced (repair measure). 87 - Tighten nut -2- on tensioning roller. - Remove tensioner 3303 -Item 1- Tightening torque Nm Tensioning roller nut 45 88
  • 49. Toothed belt for camshaft drive: check for damage (2.6l 2V and 2.8l 2V engines only) - Remove engine cover => Page 34 - Remove upper toothed belt cover. - Check condition of toothed belt: - Cracks, cross-sectional fractures - Layer separation (base, cord strands) - Base break-up - Fraying of cord strands - Surface cracks (plastic outer layer) - Traces of oil and grease Important Faults found must be rectified (repair meas- ure). 89 Toothed belt: replace Toothed belt: replace (4-cyl. petrol engines) - Removing and installing toothed belt: => 4-cylinder Engine (2-valve), Mechanical Compon- ents; Repair group 13; Dismantling and assembling engine => 4-cylinder Injection Engine (4-valve), Mechanical Components; Repair group 13; Dismantling and as- sembling engine Toothed belt: Replace (5-cyl. petrol engines) - Removing and installing toothed belt: => 5-cylinder Engine (2-valve), Mechanical Compon- ents; Repair group 13; Dismantling and assembling engine => 5-cylinder Injection Engine (4-valve), Mechanical Components; Repair group 13; Dismantling and as- sembling engine 4-cylinder 5V 1.8 litre petrol engines - Removing and installing toothed belt => 4-cyl. Engine (5-valve), Mechanical Components; Repair group 13; Dismantling and assembling engine Toothed belt and tensioning roller: replace (V6 - 5V engines) - Removing and installing toothed belt, replacing toothed belt tensioning roller: 90
  • 50. => 6-cylinder Engine (5-valve), Mechanical Compon- ents; Repair group 13; Dismantling and assembling cylinder crankcase, crank shaft and flywheel Ribbed belt: replace (V8 engines) => 8-cylinder Engine, Mechanical Components; Re- pair group 15; Cylinder head, valve gear; Removing and installing ribbed belt Toothed belt: replace (V8 engines) => 8-cylinder Engine, Mechanical Components; Re- pair group 15; Cylinder head, valve gear; Removing and installing toothed belt Toothed belt for camshaft drive and tensioning roller: replace (4-cyl. TDI engines) - Removing and installing toothed belt, replacing toothed belt tensioning roller: => 4-cyl. Diesel Direct Injection Engine (TDI), Mech- anical Components; Repair group 13; Dismantling and assembling engine - Dynamically checking and adjusting commence- ment of injection: => Diesel Direct Injection and Glow Plug System (TDI 4-cylinder); Repair group 23; Servicing diesel dir- ect injection system 91 Toothed belt for camshaft and injection pump: replace (5-cylinder diesel engines) => 5-cyl. Diesel Engine (2.4 ltr Engine), Mechanical Components; Repair group 13; Dismantling and as- sembling engine; Removing and installing toothed belt for camshaft, and toothed belt for injection pump - Dynamically checking and adjusting commence- ment of injection. => Diesel Injection and Glow Plug System (2.4 l en- gine); Repair group 23; Servicing diesel injection sys- tem Toothed belt for camshaft and injection pump: replace: (5-cylinder TDI engines) => 5-cyl. Diesel Engine (2.5 ltr Engine), Mechanical Components; Repair group 13; Dismantling and as- sembling engine; Removing and installing toothed belt for camshaft, and toothed belt for injection pump 92
  • 51. - Dynamically checking and adjusting commence- ment of injection: => Diesel Direct Injection and Glow Plug System (TDI 5-cylinder); Repair group 23; Dynamically check- ing and adjusting commencement of injection Filling in toothed belt renewal sticker - all vehicles - Fill in toothed belt renewal sticker -arrow- on lock carrier; if necessary, attach a new sticker. Manual gearbox/final drive: check oil level and top up if necessary 5-speed manual gearbox 012, front-wheel drive Special tools required ♦ Socket attachment 3357 or ♦ 17 mm hexagon socket attachment Notes: ♦ The vehicle must be absolutely horizontal when checking gearbox oil level. This work is best per- formed over an inspection pit or using a 4 - column lifting platform. ♦ The oil filler plug is on the left of the gearbox be- low the speedometer sender; it may be con- cealed by the heat shield for the drive shaft. 93 ♦ Depending on the version fitted, use either spe- cial tool 3357 or a 17 mm Allen key to loosen the oil filler plug. - Unscrew oil filler plug (arrow) to check oil level. - Check oil level using a shop-built tool, e.g. a piece of angled wire. - Specification: oil level 7 mm below bottom edge of oil filler hole Note: The oil can be filled up to the bottom edge of the oil filler hole when servicing. Important If the oil level is below the range specified, the gearbox must be checked for leaks (repair measure). It is then not sufficient to merely top up the fluid. - If there are no leaks in the gearbox, top up with SAE 75 W 90 (synthetic fluid), specification "G 052 911 A". - Fit oil filler plug. Tightening torque Nm Oil filler plug 25 5-speed and 6-speed manual gearbox 01E, front wheel drive Notes: 94
  • 52. ♦ The vehicle must be absolutely horizontal when checking gearbox oil level. This work is best per- formed over an inspection pit or using a 4 - column lifting platform. ♦ The prescribed oil level is to be adhered to ex- actly; the gearbox reacts very sensitively to over- filling. ♦ There are two different procedures for checking the gearbox oil level according to the type of fi- nal drive cover fitted. Older version: oil filler hole behind flange shaft. Newer version: oil filler hole in front of flange shaft. Older version: - Remove oil filler plug -A- (behind flange shaft) to check gearbox oil level. - Check oil level using a shop-built tool, e.g. a piece of angled wire. - Specification: oil level 6 mm below bottom edge of oil filler hole 95 Newer version: - Remove oil filler plug -B- (in front of flange shaft) to check gearbox oil level. - Specification: oil level up to lower edge of filler hole All models: Important If the oil level is below the range specified, the gearbox must be checked for leaks (repair measure). It is then not sufficient to merely top up the fluid. - If there are no leaks in the gearbox, top up with SAE 75 W 90 (synthetic fluid), specification "G 052 911 A". - Fit oil filler plug. Tightening torque Nm Oil filler plug 40 5-speed manual gearbox 01A, four-wheel drive Special tools required ♦ Socket attachment 3357 or ♦ 17 mm hexagon socket attachment Notes: 96
  • 53. ♦ The oil filler plug is on the left of the gearbox be- low the speedometer sender; it may be con- cealed by the heat shield for the drive shaft. ♦ Depending on the version fitted, use either spe- cial tool 3357 or a 17 mm Allen key to loosen the oil filler plug. - Unscrew oil filler plug (arrow) to check oil level. - Specification: oil level up to lower edge of filler hole Important If the oil level is below the range specified, the gearbox must be checked for leaks (repair measure). It is then not sufficient to merely top up the fluid. - If there are no leaks in the gearbox, top up with SAE 75 W 90 (synthetic fluid), specification "G 052 911 A". - Fit oil filler plug. Tightening torque Nm Oil filler plug 25 5-speed and 6-speed manual gearbox 01E, four- wheel drive Notes: 97 ♦ The vehicle must be absolutely horizontal when checking gearbox oil level. This work is best per- formed over an inspection pit or using a 4 - column lifting platform. ♦ The prescribed oil level is to be adhered to ex- actly; the gearbox reacts very sensitively to over- filling. ♦ There are two different procedures for checking the gearbox oil level according to the type of fi- nal drive cover fitted. Older version: oil filler hole behind flange shaft. Newer version: oil filler hole in front of flange shaft. Older version: - Remove oil filler plug -A- (behind flange shaft) to check gearbox oil level. - Check oil level using a shop-built tool, e.g. a piece of angled wire. - Specification: oil level 7 mm below bottom edge of oil filler hole 98
  • 54. Newer version: - Remove oil filler plug -B- (in front of flange shaft) to check gearbox oil level. - Check oil level using a shop-built tool, e.g. a piece of angled wire. - Specification: oil level 1 mm below bottom edge of oil filler hole All models: Important If the oil level is below the range specified, the gearbox must be checked for leaks (repair measure). It is then not sufficient to merely top up the fluid. - If there are no leaks in the gearbox, top up with SAE 75 W 90 (synthetic fluid), specification "G 052 911 A". - Fit oil filler plug. Tightening torque Nm Oil filler plug 40 99 Final drive (automatic gearbox): check oil level and top up if necessary Automatic gearbox 097, 01N - Unscrew oil filler plug -arrow-. - Specification: oil level up to lower edge of filler hole Important If the oil level is below the range specified, the final drive must be checked for leaks (repair measure). It is then not sufficient to merely top up the fluid. - If the final drive has no leaks top up with SAE 75 W 90 (synthetic oil) specification "G 052 145 A". - Fit oil filler plug. Tightening torque Nm Oil filler plug 25 - Fill in sticker for final drive oil check => Page 103. Automatic gearbox 01K, front wheel drive 100
  • 55. 01F four-wheel drive - Unscrew oil filler plug -arrow-. - Specification: oil level up to lower edge of filler hole Important If the oil level is below the range specified, the final drive must be checked for leaks (repair measure). It is then not sufficient to merely top up the fluid. - If the final drive has no leaks top up with SAE 75 W 90 (synthetic oil) specification "G 052 145 A". - Fit oil filler plug. Tightening torque Nm Oil filler plug 25 - Fill in sticker for final drive oil check => Page 103. 101 Automatic gearbox 018; four-wheel drive - Unscrew oil filler plug -arrow-. - Specification: oil level up to lower edge of filler hole Important If the oil level is below the range specified, the final drive must be checked for leaks (repair measure). It is then not sufficient to merely top up the fluid. - If the final drive has no leaks top up with SAE 75 W 90 (synthetic oil) specification "G 052 145 A". - Fit oil filler plug. Tightening torque Nm Oil filler plug 25 - Fill in sticker for final drive oil check => Page 103. 102
  • 56. Filling in sticker for final drive oil check - all vehicles - Fill in sticker for final drive oil check -arrow- on lock carrier; if necessary, attach a new sticker. 103 Engine oil: drain or extract, change oil filter Special tools required ♦ Oil filter spanner 3417 (4-cyl. petrol engines) ♦ Strap wrench Hazet 2171 - 1 (5 - cyl. petrol en- gines, V6-engines, 4-cyl. TDI engines, 5-cyl. dies- el and TDI engines) ♦ Socket attachment, long, 36 A/F ♦ Oil extractor V.A.G 1307 A or V.A.G 1358 A Note: Observe environmental requirements for disposal. - Remove noise insulation => Page 64. 4-cyl. petrol engines: - Loosen oil filter - arrow - with oil filter spanner 3417. 5 - cyl. petrol engines, 4 - cyl. TDI engines, 5 - cyl. diesel and TDI engines: - Loosen oil filter with strap wrench (e.g. Hazet 2171-1). 104
  • 57. V6 engines: - Loosen oil filter -arrow- strap wrench (e.g. Hazet 2171-1). V8 engines: - Loosen oil filter -arrow- with socket attachment 30 mm A/F. All models: - Remove oil filter. - Unscrew oil drain plug or extract engine oil. - Clean sealing surface on engine for oil filter. - Lightly lubricate rubber seal. - Screw in new filter and tighten. Notes: Note the fitting instructions on the oil filter. For engines with oil cooler 105 Important After replacement of oil filter cartridge, check clearance of hoses from oil cooler to adjacent components; if necessary correct oil cooler po- sition. - Screw in oil drain plug with new seal. - Top up engine oil, specifications => Page 119. - Observe instructions for turbo engines => Page 121. - Note different oil specifications for Audi S6 with V8 engine AHK => Page 121. Tightening torques Nm Oil drain plug 4- and 5-cyl.-engines 30 Oil drain plug V6 - 2V engines: 40 Oil drain plug V6 - 5V engines: 30 Oil drain plugs V8 engines 35 106
  • 58. Brake system: visual check for leaks and damage - Check the following components for leaks and damage: - Brake master cylinder - Brake servo - ABS hydraulic unit - Brake calipers - Brake pressure regulator - Ensure that brake hoses are not twisted. - Ensure that brake hoses do not touch any vehicle components when steering is on full lock. - Check brake hoses for porosity, blistering and brittleness. - Check brake hoses and pipes for chafing. - Check brake pipe connections and mountings for correct seating, leaks and corrosion. Important Faults found must be rectified (repair meas- ure). 107 Brake pads: check thickness Front disc brake pads: Important If the pad thickness is down to 7 mm (includ- ing backing plate), the disc brake pads have reached their wear limit and must be replaced (repair measure). Please inform the customer. - Determine thickness of outer pads by checking visually (with help of electric torch/flashlight through cut-out in wheel). - Determine thickness of inner pads by checking visually (with help of electric torch/flashlight and mirror). Notes: ♦ If the brake pads are not visible because of the type of wheel rims fitted, remove front wheels. ♦ Before removing the wheels mark the position of each wheel in relation to the brake disc and mount the wheels in the same position after completing the check. ♦ Observe notes on wheel bolts when mounting the front wheels => Page 115. 108
  • 59. Audi 100, Audi A6: - a -Pad thickness including backing plate - Wear limit: 7 mm Audi S4 (5 cyl.) > 1993: - a -Pad thickness including backing plate - Wear limit: 7 mm 109 Audi S4 (5 cyl.) 1994>, Audi S4 (V8), Audi S6: - a -Pad thickness including backing plate - Wear limit: 7 mm Rear disc brake pads: Important If the pad thickness is down to 7 mm (includ- ing backing plate), the disc brake pads have reached their wear limit and must be replaced (repair measure). Please inform the customer. - Determine thickness of outer pads by checking visually (with help of electric torch/flashlight through cut-out in wheel). - Determine thickness of inner pads by checking visually (with help of electric torch/flashlight and mirror). 110
  • 60. - a -Pad thickness including backing plate - Wear limit: 7 mm Notes: ♦ If the brake pads are not visible because of the type of wheel rims fitted, remove rear wheels. ♦ Before removing the wheels mark the position of each wheel in relation to the brake disc and mount the wheels in the same position after completing the check. ♦ Observe notes on wheel bolts when mounting the rear wheels => Page 115. Rear drum brake linings: - Pull plug out of inspection hole in backplate -ar- row-. - Determine thickness of brake linings by checking visually, using an electric torch (flashlight). - a -Lining thickness without brake shoe - Wear limit: 2.5 mm Important If the pad thickness is down to 2.5 mm (not in- cluding backing plate), the drum brake linings have reached their wear limit and must be re- placed (repair measure). Please inform the cus- tomer. 111 Underseal: visual check for damage - When performing visual check, check underbody, wheel housings and side members. Important Faults found must be rectified (repair meas- ure). Track rod ends: check play, attachment and protective boots Note: The test must be made with vehicle raised on a lift- ing platform (wheels free to move). - Check play by moving track rods and wheels. - There should be no play - Check that lock nuts are secure (40 Nm). - 1 -Lock nut on wheel side, right-hand thread - 2 -Lock nut on track rod side, left-hand thread - Check protective boot - arrow - for damage and correct seating. 112
  • 61. Tyres: check and correct condition, wear pattern, tread depth and inflation pres- sures Notes: ♦ In the interests of driving safety, only tyres of the same type and tread pattern should be fitted on a vehicle. ♦ On four wheel drive vehicle tyres of the same type and tread pattern must be used. Otherwise the centre differential may be damaged. - Check tyre tread and side walls for damage and remove any foreign bodies. - Check tyres for scuffing, one-sided wear, porous side walls, cuts and fractures. Important The customer must be informed of any de- fects. Checking tyre wear pattern - The wear pattern of the front tyres indicates whether the toe and camber have to be checked - Feathering on tread indicates incorrect toe set- ting. - One-sided tread wear is mainly caused by incor- rect camber. 113 Note: If the above types of wear are found, check wheel alignment to determine the cause (repair measure). Checking tyre tread depth - Minimum permissible tread depth: 1.6 mm Notes: ♦ This value may vary for individual countries ac- cording to legislation. ♦ The minimum tread depth is reached when the tyres have worn down level with the 1.6 mm high tread wear indicators - arrows- positioned at intervals around the tyre. ♦ If the tread depth is approaching the minimum permissible tread depth, the customer must be informed. Inflating to correct pressures The correct inflation pressures for summer tyres are listed on the sticker on the inside of the tank flap. Notes: ♦ Please note that the inflation pressures listed on the sticker apply to cold tyres. When the tyres are warm, the actual pressures will be higher, but must not be reduced. ♦ When using winter tyres, pressures should be increased by 0.2 bar. Spare wheel 114
  • 62. • Spare wheel with standard-size tyre - Inflate to the maximum pressure specified for the vehicle. • Temporary (compact) spare wheel: The correct inflation pressure is indicated on the side wall. Notes: ♦ The tyre valves must be closed with dust caps. Otherwise, dirt can obstruct the valve pin and cause loss of air. ♦ On vehicles with steel rims and wheel covers, check the tyre valve extensions. Damage and dirt can cause leaks. Replace if necessary. Wheel bolts: tighten to specified torque Wheel cover Puller - 1 - for removing the wheel cover is in the vehicle tool kit. 115 Trim cap - On vehicles with light-alloy wheels and trim caps insert a screwdriver in the recess and lever the trim cap off the wheel rim. Wheel bolt locks - Pull trim cap off wheel bolt lock. - On wheel rims with recessed wheel bolts, insert the hook -2- at the side of the bolt, turn it slightly and pull the cap off. - Turn key -1- anti-clockwise in wheel bolt lock and remove together with wheel bolt lock. - To re-install, push wheel bolt lock as far as it will go onto wheel bolt. - Turn key clockwise in lock and remove key. - When refitting the cap, ensure that it engages all the way round. Note: Ensure that the wheel bolts are tightened in a diag- onal sequence to the following tightening torque: Tightening torque Nm Wheel bolts 120 116
  • 63. Correct installation of wheels - When fitting the road wheels note the following points to ensure that the wheels remain secure at all times. • Always tighten the wheel bolts to the specified torque, excessive torque can distort the wheel bolt seats in the rim. • When fitting a wheel do not torque down the first wheel bolt immediately (e.g. with an impact wrench), as this would prevent the other bolts from centring the wheel properly when they are screwed in. The rim could then come loose even though the bolts have been tightened to the spe- cified torque. • Before installing the wheels examine the seats of the wheel bolts and the contact surfaces between the rims and the hubs for rust and cor- rosion. Clean off these parts if necessary other- wise this can affect the clamping force of the bolts after installation and the rims can come loose. 117 Important ♦ If the points listed above are not observed the wheel mountings can come loose and the wheel bolt seats can become distorted. ♦ This distortion may be very slight and not visible to the naked eye. ♦ Even this slight distortion of the wheel bolt seats can prevent the rims from being held firmly and the wheels will come loose repeatedly. Engine oil: fill The engine is filled with a high quality multigrade oil at the factory which can be used all year round, ex- cept in extremely cold climates. Viscosity grades Note: The oil does not need changing for brief variations of outside temperature beyond the temperature ranges shown. 118
  • 64. Viscosity grades for petrol, diesel and TDI en- gines (but not for Audi S6 with V8 engine AHK): Select the viscosity grade of the oil according to the chart. - A - Multigrade high lubricity oils, specification => Page 120 - B - Multigrade oils, specification => Page 120 Viscosity grades for Audi S6 with V8 engine AHK: Select the viscosity gradeof the oil according to the chart 1). - A - Multigrade high lubricity oils, specification => Page 121 1) If these oils are not available engine oils with other viscosity grades may be used as an emer- gency measure as long as they conform to VW standard 500 00 => Page 121. Oil specifications The specifications listed here should appear on the container - either singly or together with other spe-ci- fications. 119 Note: When topping up, different types of oil may be mixed if necessary. Oil specification for petrol engines (but not for Audi S6 with V8 engine AHK) and diesel engines (but not for TDI engines): - A - High lubricity multigrade oils, specification VW 500 00 1) High - lubricity multigrade oils, specification VW 502 00 2) - B - Multigrade oils, specification VW 501 01 1) - - Multigrade oils, Specification API-SF 3)or API- SG 3) 1) The date given after the VW specification must not be earlier than 10.97. 2) These oils are particularly suitable for tur- bocharged petrol engines. 3) These oils should only be used if the approved engine oils are not available. Oil specifications for TDI engines: - A - High-lubricity multigrade oils, specification VW 500 00 1) (only in combination with specifica- tion VW 505 00) - B - Multigrade oils, specification VW 505 00 1) - - Multigrade oils, specification VW 501 01 1) (only in conjunction with specification VW 505 00) 120
  • 65. - - Multigrade oils, specification API-CD (should only be used for emergency topping up) 1) The date given after the VW specification must not be earlier than 10.97. Oil specifications for Audi S6 with V8 engine AHK: - A - High lubricity multigrade oils, specification VW 500 00 1) 1) The date given after the VW specification must not be earlier than 10.97. - Top up engine oil. Capacities with filter replacement: => ELSA Maintenance table Engines with turbocharger: - When the engine oil and oil filter have been changed, it is important to note the following after starting the engine for the first time: - The engine must only run at idling speed until the oil pressure warning lamp in the dash panel insert goes out.Do not press the accelerat- or!This could cause severe damage to the tur- bocharger. - The full oil pressure is only reached when the warning lamp goes out, and the accelerator can then be pressed. All models: - Finally, check the engine oil level => Page 122. 121 Engine: check oil level Test requirements: • Engine oil temperature at least 60 °C • Vehicle must be level (horizontal) • Wait a few minutes after switching off the en- gine to allow the oil to flow back into the sump. - Pull out the dipstick, wipe with a clean cloth and insert again to stop. - Pull out the dipstick again and read off the oil level. Markings on oil dipstick: - a -Oilmust not be topped up. - b -Oil may be topped up. The oil level may rise as far as area -a- after topping up. - c -Oilmustbe topped up. The oil level is suffi- cient if somewhere in area -b- (grooved area) after topping up. Note: The oil level must not be above marking -a- on the dipstick. 122
  • 66. Automatic gearbox: change ATF (except 01N gearbox) Engine Gearbox Page 4- and 5-cyl. engines > 12.94 V6 engines (front-wheel drive) > 02.92 097 124 5 cyl. TDI engines > 05.94 V6 engines (front-wheel drive) 03.92 > 05.94 01K 128 5 cyl. TDI engines 06.94 > V6 engines (front-wheel drive) 06.94 > 01K 133 5-cyl. 4V engines > 05.94 V6 engines (four-wheel drive) > 05.94 01F 128 5-cyl. 4V engines 06.94 > V6 engines (four-wheel drive) 06.94 > 01F 133 V8 engines 018 137 Notes: ♦ Use only ATF with the part no. G 052 162 A. (colour: clear/yellow). Do not use any additives! ♦ The engine must not be started or towed without ATF in gearbox. ♦ When filling is started, the ATF temperature must not be higher than 35 °C. ♦ Observe environmental requirements for dispos- al. 123 Special tools, testers and auxiliary items required ♦ Drip tray V.A.G 1306 ♦ Oil extractor V.A.G 1358 A with oil suction probe V.A.G 1358 A/1 (automatic gearbox 097 only) ♦ Fault reader V.A.G 1551 with diagnostic cable V.A.G 1551/1 ♦ ATF filling system V.A.G 1924 and protective goggles (not for automatic gearbox 097) Automatic gearbox 097 Draining ATF - Draw off ATF with oil extractor V.A.G 1358 A with oil suction probe 1358/A 1. or - Raise vehicle. - Place drip tray V.A.G 1306 underneath the gear- box. 124
  • 67. - Unscrew union nut on lower ATF filler pipe -5- and pull filler pipe out of oil pan. - Allow the ATF to drain out. - Re - attach ATF filler pipe: tightening torque 80 Nm. Filling ATF - First fill approx. 3.0 litres of ATF into the filler pipe using a funnel. - Move selector lever to position "P". - Start engine and run at idling speed. - With the engine idling press the brake pedal and shift the selector lever through all the selector lever positions leaving the selector lever 2 ... 3 seconds in each position. - Move selector lever to position "P". - Pull out ATF dipstick and wipe clean using a lint- free cloth. - Insert the ATF dipstick all the way into the ATF filler pipe and pull it out again. 125 - Check ATF level on dipstick. - ATF should be filled up to the 20 °C-mark when cold. - Switch ignition off. Checking ATF level Test requirements: • Gearbox not in emergency running mode, ATF temperature between 50 ... 70 °C. • Vehicle must be level (horizontal) • Set the selector lever to "P". • The air conditioner and heating system must be switched off. - Connect V.A.G 1551 => Page 23. - Start engine and run at idling speed. - Enter "1" to select "Rapid data transfer". - Enter "02" for address word "Gearbox electronics" and confirm entry with Q key. - Press ⇒ key to continue. - Enter "08" to select the function "Reading meas- ured value block" and confirm entry with Q key. Reading measured value block Q Enter display group number XXX Indicated on display - Enter "005" to select display group number "005" and confirm entry with Q key. Read measured value block 5 ⇒ 1 2 3 4 Indicated on display - Read off ATF temperature in display zone 1. - When the ATF has reached a temperature of about. 50 °C, pull out the ATF dipstick and wipe it clean using a lint-free cloth. 126
  • 68. - Insert the ATF dipstick all the way into the ATF filler pipe and pull it out again. - Check ATF level on dipstick. • If the ATF level is between the min. and max. markings at a temperature of 50 ... 70 °C, the ATF level is OK. Notes: ♦ The ATF level must not be checked at temperat- ures above 70 °C. If necessary wait for the ATF to cool down again. ♦ The markings on the ATF dipstick are for an ATF temperature of 60°C. Important An insufficient ATF filling as well as filling to excess affects the function of the gearbox. • If ATF level is too low: - Fill up with ATF using a clean funnel. Note: Use only ATF "G 052 162 A." (colour: clear/yellow). Do not use any additives! - With vehicle stationary and engine running, move selector lever through all selector lever positions. - Check ATF level again at test temperature. • If ATF level is too high: 127 - Draw off excess ATF with oil extractor V.A.G 1358 A and oil suction probe 1358/A 1. - Check ATF level again at test temperature. Automatic gearbox 01K, front wheel drive 01F four-wheel drive > 1994 Draining ATF - Raise vehicle. - Place drip tray V.A.G 1306 underneath the gear- box. - Unscrew ATF drain plug -arrow 1-. - Allow the ATF to drain out. Filling ATF - Fit ATF drain plug with new seal and screw in. - Pull sealing cap -arrow- off ATF filler pipe. - First put approx. 2.7 litres of ATF into the filler pipe using a funnel. - Move selector lever to position "P". - Start engine and run at idling speed. - With the engine idling press the brake pedal and shift the selector lever through all the selector lever positions leaving the selector lever 2 ... 3 seconds in each position. - Move selector lever to position "P". 128
  • 69. - Measure ATF level using ATF dipstick. - For the following vehicles, check the ATF level using the dipstick marked "02": - All vehicles with V6 engines - Audi S4 up to vehicle identification number 4A RN 033 426 ( > approx. 11.93) Note: Vehicles requiring "02" dipstick have "02" marked on ATF filler pipe -arrow-. - For the following vehicles, check the ATF level using the dipstick marked "03": - All with 5 cyl. TDI engine - Audi S4 from vehicle identification number 4A RN 033 427 (approx. 11.93 >) Note: Vehicles requiring "03" dipstick have "03" marked on ATF filler pipe -arrow-. - Use a lint - free cloth to wipe the ATF dipstick clean. - Insert the ATF dipstick all the way into the ATF filler pipe and pull it out again. - Check ATF level on dipstick. 129 - ATF should be filled up to the 20 °C mark when cold. - Switch ignition off. Tightening torque Nm ATF drain plug 40 Checking ATF level Test requirements: • Gearbox not in emergency running mode, ATF temperature between 50 ... 70 °C. • Vehicle must be level (horizontal) • Set the selector lever to "P". • The air conditioner and heating system must be switched off. - Connect V.A.G 1551 => Page 23. - Start engine and run at idling speed. - Enter "1" to select "Rapid data transfer". - Enter "02" for address word "Gearbox electronics" and confirm entry with Q key. 4A0927156AL AG4 01F 2.8l 5V RoW D26 ⇒ Coding 00001 WSC 06744 If following display appears (example): - Check control unit identification. Control unit identification containing code "01D". - Press ⇒ key to continue. - Enter "08" to select the function "Reading meas- ured value block" and confirm entry with Q key. Reading measured value block Q Enter display group number XXX Indicated on display 130