Audi A3 1997 Service Download Page 47 | Manualshive

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Audi A3 1997 Service Download Page 47

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.

2.7 - Replacing voltage regulator - Bosch alternator

1 Oval cross-head bolts

◆ 1 Nm

2 Protective cap

◆ 3 retainer tabs

3 Oval cross-head bolts

◆ M4 = 2 Nm

4 Voltage regulator

◆ Removing:

- Screw out bolts -Item

1

- and detach protective cap -Item

2

-

- Screw out bolts -Item

3

- and detach voltage regulator

◆ Carbon brush wear limit: 5 mm

5 Alternator

Audi A3 1997 ➤

Electrical system - Edition 10.2003

2.7 - Replacing voltage regulator - Bosch alternator

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Summary of Contents for A3 1997

Page 1: ...ole is not permitted unless authorised by AUDI AG AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document Copyright by AUDI AG Audi A3 1997 E...

Page 2: ...r Group 27 Starter Current supply 90 Gauges Instruments 92 Windscreen wipe and wash system 94 Lights Lamps Switches exterior 96 Lights Lamps Switches interior 97 Wiring Technical information should al...

Page 3: ...hout free wheel 41 2 10 Removing and installing ribbed belt pulley with free wheel 42 3 Removing and installing starter 43 3 1 Removing and installing starter 43 3 2 Vehicles with 4 cylinder petrol en...

Page 4: ...Servicing headlights up to Model Year 2000 89 1 1 Servicing headlights up to Model Year 2000 89 1 2 Exploded view of halogen headlight 90 1 3 Exploded view of gas discharge headlight 92 1 4 Removing...

Page 5: ...ing fog lights vehicles as of Model Year 2001 130 4 2 Removing and installing fog lights 131 4 3 Replacing fog light bulbs 132 4 4 Adjusting fog lights 133 5 Side mounted turn signal indicators 134 5...

Page 6: ...witch 5 door model 167 1 14 Removing and installing front passenger s window lifter switch 5 door model 168 1 15 Removing and installing rear door window lifter switch 169 1 16 Removing and installing...

Page 7: ...n socket for towing hitch 187 6 3 Terminal assignment at connection socket for towing hitch 188 97 Wiring 189 1 Relay carriers fuse carriers 189 1 1 Relay carriers fuse carriers 189 1 2 Removing and i...

Page 8: ...es in part or in whole is not permitted unless authorised by AUDI AG AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document Copyright by AUD...

Page 9: ...m Hazard warning information and safety regulations relating to lead acid batteries Pay attention to information given on battery in electrical system workshop manual and in owner s manual 2 Danger of...

Page 10: ...up to Model Year 2000 Attention On vehicles fitted with telematics system activate telematics control unit service mode before disconnecting battery Radio Telephone Navigation Repair Group 91 Heed if...

Page 11: ...le shoe of positive wire Unfasten nut 2 several turns and disconnect pole shoe of positive wire from battery post Release retainer for main fuse box To do so press down front edge of retainer arrow 1...

Page 12: ...matics control unit service mode before disconnecting battery Radio Telephone Navigation Repair Group 91 Heed if necessary obtain code for vehicles with encoded radio radio navigation system RNS Switc...

Page 13: ...trip of battery bracket Lift battery out of engine compartment Install battery Page 7 1 5 Removing battery Audi S3 Removing Attention On vehicles fitted with telematics system activate telematics cont...

Page 14: ...fitted open upper protective cover of battery A velcro fastener Press release tabs arrows and open lid B of main fuse box Unfasten nut 3 several turns and disconnect pole shoe of earth wire from batt...

Page 15: ...y Page 7 1 6 Installing battery Note Batteries from the Audi parts range feature a base strip adapter for matching to different fastening strips When and how the base strip adapter is to be used is de...

Page 16: ...ctric window lifters in line with owner s manual Deactivate telematics control unit service mode Radio Telephone Navigation Repair Group 91 For further operations after re connecting power supply refe...

Page 17: ...roperly vented On batteries with no central gas venting hose pipe it is important to ensure that opening in top cover arrow is not clogged Checking firm attachment of battery Possible dangers if batte...

Page 18: ...ewed on for charging voltage measurement and load measurement Visually inspect battery before performing measurements e g no load voltage specific gravity of electrolyte or battery load test Such insp...

Page 19: ...lectrolyte level can then be checked by way of a visual inspection of the inside of the battery The electrolyte level must coincide with the internal level mark plastic web This corresponds to the out...

Page 20: ...Electrolyte level too high Note If the electrolyte level is too high escaping electrolyte mixture of sulphuric acid and water will cause damage outside the battery e g on components in the engine comp...

Page 21: ...following notes as otherwise correct measurement is not guaranteed Notes Always disconnect earth strap if no load voltage is measured with battery in vehicle Loads must not have been connected to bat...

Page 22: ...of 12 7 V Replace battery if no load voltage is not OK Install in reverse order paying attention to the following Connect battery Action to be taken Page 7 1 11 Checking specific gravity of electroly...

Page 23: ...e in normal climatic zones Specific gravity of electrolyte in kg dm3 Discharged 1 12 Semi charged 1 20 Well charged 1 28 Charge state in the tropics Specific gravity of electrolyte in kg dm3 Discharge...

Page 24: ...vent of loss or damage make exclusive use of genuine caps of the same type The caps must be fitted with an O ring seal 1 12 Measuring voltage under load Special tools and workshop equipment required B...

Page 25: ...ng and only increases again slowly 1 13 Charging battery Special tools and workshop equipment required Battery charger The battery should be charged using a V A G battery charger e g V A G 1471 V A G...

Page 26: ...attery capacity i e for a 60 Ah battery approx 6 A Switch on battery charger Install in reverse order paying attention to the following Connect battery Action to be taken Page 7 Explanatory notes on e...

Page 27: ...3 A amps Charge battery Page 17 The charging voltage Umax must not exceed 14 4 V Rapid charging is never to be implemented on exhausted batteries 2 Removing and installing alternator 2 1 Removing and...

Page 28: ...rise plugs out of cover in front of intake manifold Remove engine cover and cover in front of intake manifold arrows Note Fig shows bolted on engine cover Vehicles with 1 8 l engine Remove engine cove...

Page 29: ...ner Detach ribbed belt Unplug connector 2 Unscrew wire 1 at alternator Note If fitted unscrew clamp with alternator detached and lay bare wire Screw out bolts arrows Detach alternator and guide it upw...

Page 30: ...ht by AUDI AG Ribbed belt routing on vehicles with no air conditioner Ribbed belt routing on vehicles with air conditioner Connect battery Action to be taken Page 7 Start engine and check belt running...

Page 31: ...Copyright by AUDI AG Removing Remove engine cover arrows Remove cover in front of intake manifold arrows Pull off air hose 2 at throttle valve control part Note Before removing mark direction of ribb...

Page 32: ...mation in this document Copyright by AUDI AG Use mandrel T10060 or offset Allen key to lock ribbed belt tensioner Detach ribbed belt Detach pipe for secondary air system from holder at engine arrows S...

Page 33: ...connector 2 Unscrew wire 1 at alternator Unscrew clamp at alternator Screw out bolts arrows Take out alternator Installing Install in reverse order paying attention to the following To facilitate pos...

Page 34: ...ion in this document Copyright by AUDI AG Ribbed belt routing on vehicles with air conditioner Connect battery Action to be taken Page 7 Start engine and check belt running Tightening torques Componen...

Page 35: ...ee or accept any liability with respect to the correctness of information in this document Copyright by AUDI AG Removing Remove engine cover arrows Remove cover in front of intake manifold arrows Scre...

Page 36: ...2 from intake manifold Note Coolant hose 1 need not be detached Screw out bolts 2 and 3 and pull holder 4 off guide tube for dipstick Disengage coolant hose 1 at holder Lay aside holder with connected...

Page 37: ...correctness of information in this document Copyright by AUDI AG Use mandrel T10060 or offset Allen key to lock ribbed belt tensioner Detach ribbed belt Unplug connector 2 Unscrew wire 1 at alternato...

Page 38: ...tate positioning of alternator drive back bushings for retaining bolts slightly Make sure ribbed belt is properly positioned and correctly routed Ribbed belt routing on vehicles with no air conditione...

Page 39: ...Remove lower air pipe arrows Remove centre and right noise insulation arrows Note Before removing mark direction of ribbed belt with chalk or felt tipped pen Running a used belt in the opposite direc...

Page 40: ...n this document Copyright by AUDI AG Remove tensioner for ribbed belt arrows If fitted remove auxiliary fan on right Use cardboard to protect radiator against damage if necessary Note Leave wires conn...

Page 41: ...n Refrigerant circuit of air conditioner is never to be opened Unscrew air conditioner compressor lower together with connected refrigerant hoses and tie up with wire at towing eye arrow Note Use adhe...

Page 42: ...er paying attention to the following To facilitate positioning of alternator drive back bushings for retaining bolts slightly Vehicles with air conditioner To facilitate positioning of air conditioner...

Page 43: ...belt routing on vehicles with air conditioner Connect battery Action to be taken Page 7 Start engine and check belt running Tightening torques Component Nm Alternator to bracket for ancillaries 25 Te...

Page 44: ...lity with respect to the correctness of information in this document Copyright by AUDI AG Removing Pull dipstick 1 out of guide tube Pull off engine cover arrows Re insert dipstick in guide tube Lay b...

Page 45: ...AG Note Before removing mark direction of ribbed belt with chalk or felt tipped pen Running a used belt in the opposite direction could destroy it Swivel tensioner in direction of arrow to slacken of...

Page 46: ...to the following To facilitate positioning of alternator drive back bushings for retaining bolts slightly Make sure ribbed belt is properly positioned and correctly routed Ribbed belt routing on vehic...

Page 47: ...nt Copyright by AUDI AG 2 7 Replacing voltage regulator Bosch alternator 1 Oval cross head bolts 1 Nm 2 Protective cap 3 retainer tabs 3 Oval cross head bolts M4 2 Nm 4 Voltage regulator Removing Scre...

Page 48: ...AG 2 8 Replacing voltage regulator Valeo alternator 1 Alternator 2 Voltage regulator Removing Unscrew nuts Item 5 and detach protective cap Item 4 Unscrew bolt Item 6 and nuts Item 7 and detach voltag...

Page 49: ...belt pulley without free wheel Special tools and workshop equipment required Socket attachment 3310 Removing Support nut with socket attachment 3310 and turn alternator shaft clockwise Detach ribbed...

Page 50: ...bed belt pulley with free wheel Special tools and workshop equipment required Multi point adapter 3400 Removing Support pulley with multi point adapter 3400 and turn alternator shaft clockwise Install...

Page 51: ...tics system activate telematics control unit service mode before disconnecting battery Radio Telephone Navigation Repair Group 91 Heed if necessary obtain code for vehicles with encoded radio radio na...

Page 52: ...y with respect to the correctness of information in this document Copyright by AUDI AG Take wiring out of guide Screw out bolt arrow Detach power steering pressure pipe Unscrew wire guide Screw out to...

Page 53: ...llowing Install battery carrier and battery Connect battery Action to be taken Page 7 Tightening torques Component Nm Starter to gearbox M10 45 M12 65 Holder for power steering pressure pipe to starte...

Page 54: ...pump 1 from air cleaner housing Detach air hose at air mass meter 2 Unplug connector for air mass meter 3 Screw out bolts 4 and 5 Take out air cleaner housing Use screwdriver to press selector lever c...

Page 55: ...ment Copyright by AUDI AG Pull plastic cap 1 off solenoid switch Unplug connector 2 Unscrew connector 1 Screw out bolts 1 and 2 Lift out starter Installing Install in reverse order paying attention to...

Page 56: ...gation system RNS Disconnect battery earth strap with ignition switched off Note Action to be taken after re connecting power supply Page 7 1 2 dEF display on trip recorder If control unit in dash pan...

Page 57: ...tches of connectors arrow and unplug connectors Installing Install in reverse order paying attention to the following After installation check operation of dash panel insert If operation is OK enter i...

Page 58: ...play Note Cover panel C is to be removed if dash panel insert is replaced on vehicles with ambient temperature display or if ambient temperature display is retrofitted Highline dash panel insert 1 Mai...

Page 59: ...l functions C Cover panel for vehicles with no ambient temperature display Note Cover panel C is to be removed if dash panel insert is replaced on vehicles with ambient temperature display or if ambie...

Page 60: ...nnector 1 Terminal 15 2 Right turn signal indicator 3 Speedometer output 1 4 Not used 5 Fuel gauge sender 6 Airbag 7 Terminal 31 sensor earth 8 Coolant temperature 9 Terminal 31 load earth 10 Oil pres...

Page 61: ...t for external buzzer actuation not used at present 9 Input for external gong actuation not used at present 10 Tank warning output signal for engine control unit not used at present 11 Standing time o...

Page 62: ...e 11 On board computer reset 12 Clock signal for radio frequency display 13 Data signal for radio frequency display 14 On board computer left 15 Enable signal for radio frequency display 16 Reversing...

Page 63: ...levelling suspension not used at present 15 Terminal 58d 16 Trailer turn signal indicator 17 Main beam 18 Left turn signal indicator 19 ABS 20 Terminal 58b 21 Driver s door contact 22 Coolant low 23 T...

Page 64: ...t used at present 11 Standing time output 12 Air conditioner shutoff 13 Parking brake 14 Electronic throttle 15 Side light 16 Not used 17 Transponder 2 18 Not used 19 Not used 20 Not used 21 Not used...

Page 65: ...16 Reversing light dipped beam lamp check 17 Glow plug relay with diesel engine only undervoltage monitoring in dash panel insert is suppressed during glow period 18 On board computer right 19 Brake...

Page 66: ...gauge sender 1 Switched positive connection of electric fuel pump 2 Wiring between fuel gauge sender and dash panel insert fuel gauge 3 Fuel gauge sender earth sensor earth 4 Electric fuel pump earth...

Page 67: ...ent at coolant temperature sender G2 Coolant temperature sender is located at thermostat connection Carefully release 4 pin connector arrow and unplug Note Fig shows vehicle with 1 8 l turbo engine As...

Page 68: ...working on electrical system On vehicles fitted with telematics system activate telematics control unit service mode before disconnecting battery Radio Telephone Navigation Repair Group 91 Heed if nec...

Page 69: ...go and tilt it downwards Pull off surround 1 in direction of arrow Screw out bolts arrows Pull out dash panel insert to front If fitted cut open cable ties on back of dash panel insert Release catches...

Page 70: ...mps in dash panel insert are fitted with light emitting diodes Dash panel insert must be replaced in the event of warning lamp failure Midline dash panel insert A Green 32 pin connector B Blue 32 pin...

Page 71: ...9 Terminal 31 load earth 10 Oil pressure 2 high 11 Engine speed signal 12 Air conditioner shutoff 13 Electronic throttle glow period warning lamp 14 Self levelling suspension 15 Terminal 58d 16 Trail...

Page 72: ...ndicator 8 External buzzer 9 External gong 10 Airbag 11 Standing time output 12 Terminal 61 13 Parking brake BRAKE 14 CHECK 15 Oil level oil temperature 16 Not used 17 Transponder 2 18 CAN high speed...

Page 73: ...7 CAN high speed display screen 8 Front passenger s door contact 9 Rear right door contact 10 Rear left door contact 11 Enable 12 Clock 13 Data 14 Brake light 15 Washer fluid level 16 Reversing light...

Page 74: ...clock earth 2 6 Terminal assignment at coolant temperature sender G2 Coolant temperature sender is located at thermostat connection Carefully release 4 pin connector arrow and unplug Note Fig shows v...

Page 75: ...antee or accept any liability with respect to the correctness of information in this document Copyright by AUDI AG Radio clock is integrated into dash panel insert and is not available as a separate r...

Page 76: ...before working on electrical system On vehicles fitted with telematics system activate telematics control unit service mode before disconnecting battery Radio Telephone Navigation Repair Group 91 Hee...

Page 77: ...ew hexagon nuts Use puller T10130 to pull wiper arms 1 off wiper shaft and detach Removing wiper frame with linkage and wiper motor Pull off rubber seal 2 of plenum chamber cover Lift plenum chamber c...

Page 78: ...ve tape to stop wing becoming scratched Detaching wiper motor from wiper frame Use pressing off lever 80 200 to prise wiper linkage off ball end arrow Unscrew nut 2 Pull crank 1 off wiper motor Unscre...

Page 79: ...el with wiper frame and tighten nut 2 to 18 Nm Dimension x on left Dimension x on right Note Wiper frame has been removed in Fig Set park position of wiper blades Page 71 Tightening torque Component N...

Page 80: ...4 Eliminating wiper judder Special tools and workshop equipment required Wiper adjustment tool 3358 Possible causes of wiper judder Scratches on window Wiper rubber come loose or cracked Wiper arms b...

Page 81: ...m 2 out of adjustment tool Re insert wiper arm 2 in wiper arm adjustment tool 3358 and fix in position again with lock screw 3 Compare angle displayed to specification Page 73 If necessary repeat sett...

Page 82: ...to the correctness of information in this document Copyright by AUDI AG 2 2 Removing and installing washer fluid reservoir Removing Remove engine covers Audi A3 with 1 8 l turbo engine Pull off air h...

Page 83: ...from body 4 Leave hoses connected to fuel filter All models Unplug connectors 2 and 5 Unscrew bolt 1 and nut 3 Unplug connectors 2 and 5 Lift out washer fluid reservoir Installing Install in reverse o...

Page 84: ...num chamber cover Lift plenum chamber cover 3 such that washer fluid pipe can be disconnected Unplug connector if fitted Detach plenum chamber cover 3 Use small screwdriver to press back retainer tab...

Page 85: ...on windscreen Dimension a 240 50 mm Dimension b 190 50 mm Dimension c 320 50 mm Aim adjustment tool at the points from each of the spray jets 3 Servicing rear window wipe wash system 3 1 Servicing re...

Page 86: ...ect to the correctness of information in this document Copyright by AUDI AG 3 2 Removing and installing rear wiper Note Before removing wiper arm make sure wiper motor is in park position 1 Wiper blad...

Page 87: ...G does not guarantee or accept any liability with respect to the correctness of information in this document Copyright by AUDI AG Removing Use small screwdriver to carefully prise off cap 2 Unscrew se...

Page 88: ...ng Install in reverse order paying attention to the following With wiper arm still detached switch rear wiper on and off and allow to return to park position Attach wiper arm 5 with wiper blade 1 to d...

Page 89: ...DI AG does not guarantee or accept any liability with respect to the correctness of information in this document Copyright by AUDI AG 3 3 Removing and installing rear wiper motor 1 Fluid hose 2 Securi...

Page 90: ...respect to the correctness of information in this document Copyright by AUDI AG Removing Remove rear wiper Page 78 Remove trim at bottom of tailgate General Body Repairs Interior Repair Group 70 Unplu...

Page 91: ...spect to the correctness of information in this document Copyright by AUDI AG Installing Install in reverse order paying attention to the following Note Carefully insert rubber seal 4 in hole in rear...

Page 92: ...4 Removing and installing spray jet Removing Carefully prise off cap 1 of spray jet arrow Pull spray jet 2 out of connection pipe Installing Install in reverse order paying attention to the following...

Page 93: ...ck whether wiper blade comes to rest on upper edge of hatched area at bottom of rear window If necessary slacken off wiper arm align it correctly and then tighten nut Tightening torque Component Nm Wi...

Page 94: ...ol and set wiper arm 2 to specified angle arrows Page 73 Slacken off lock screw 3 and pull wiper arm 2 out of adjustment tool Re insert wiper arm 2 in wiper arm adjustment tool 3358 and fix in positio...

Page 95: ...o radio navigation system RNS Disconnect battery earth strap with ignition switched off Note Action to be taken after re connecting power supply Page 7 4 2 Removing and installing spray jets of headli...

Page 96: ...ions with standard hose clamps Parts List Use pliers V A G 1275 to fit hose clamp Install front bumper General Body Repairs Exterior Repair Group 63 Tightening torque Component Nm Spray jet to bumper...

Page 97: ...em On vehicles fitted with telematics system activate telematics control unit service mode before disconnecting battery Radio Telephone Navigation Repair Group 91 Heed if necessary obtain code for veh...

Page 98: ...tion in this document Copyright by AUDI AG 1 2 Exploded view of halogen headlight 1 Headlight housing 2 Speed nut 3 6 Nm 4 Side light bulb 12 V 5 W Bulb replacement Page 102 5 Bulb holder For side lig...

Page 99: ...n this document Copyright by AUDI AG 7 Housing cover With seal 8 Dipped beam bulb H7 12 V 55 W Bulb replacement Page 101 9 Left right headlight range control motor V48 V49 Removing and installing Page...

Page 100: ...correctness of information in this document Copyright by AUDI AG 1 3 Exploded view of gas discharge headlight 1 Gas discharge lamp starter unit N195 Removing and installing Page 106 2 Connector 3 Head...

Page 101: ...DI AG 8 Main beam bulb H7 12 V 55 W Bulb replacement Page 104 9 Housing cover With seal 10 Retaining ring For gas discharge lamp 11 Gas discharge lamp 35 W D2S Bulb replacement Page 103 12 Left right...

Page 102: ...DI AG AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document Copyright by AUDI AG 13 O ring Replace if damaged or leaking 14 2 5 Nm 15 Brack...

Page 103: ...iability with respect to the correctness of information in this document Copyright by AUDI AG 1 4 Removing and installing headlights Removing Left headlight If fitted remove front left cover arrows Ri...

Page 104: ...th turn signal indicator beneath headlight and at radiator grille as protection for paintwork Release catch 1 at turn signal indicator housing with cross head screwdriver 2 by giving 1 4 turn to left...

Page 105: ...ttention to the following Engage lug 1 of headlight in guide 2 in centre area Align headlight with body contours gap widths and secure Tighten bolts arrows Following installation adjust headlights Pag...

Page 106: ...1 and 2 the same number of turns For lateral adjustment only turn adjusting screw 2 1 6 Adjusting headlights gas discharge headlights Special tools and workshop equipment required VAS 5051 with VAS 50...

Page 107: ...play on VAS 5051 1 Enter display group Use keypad 2 to enter 001 for Display group number 001 and confirm by touching Q key Display on VAS 5051 1 Basic setting 2 Display group 1 3 Wait Headlights are...

Page 108: ...To adjust height give adjusting screws 1 and 2 the same number of turns For lateral adjustment only turn adjusting screw 2 Display on VAS 5051 Touch s key to switch to display group 002 1 Basic settin...

Page 109: ...e 95 1 8 Replacing dipped beam bulb halogen headlight Preparation for bulb replacement Page 101 Removing Detach cover from headlight housing Unplug connector 1 at dipped beam bulb Disengage spring cli...

Page 110: ...ights Unplug connector 2 at main beam bulb Disengage spring clip 3 and take bulb 1 out of housing Installing Install in reverse order paying attention to the following Insert new bulb in housing takin...

Page 111: ...for dipped beam gas discharge headlight Attention High voltage Always disconnect battery earth strap before working on gas discharge headlight components marked with yellow high voltage symbols Remov...

Page 112: ...adlight Page 97 1 12 Replacing main beam bulb gas discharge headlight Preparation for bulb replacement Page 101 Removing Detach cover from headlight housing Unplug connector 3 at main beam bulb Diseng...

Page 113: ...der taking care not to touch glass bulb with bare hands Press holder into reflector until it is felt to engage Close housing cover 1 14 Replacing turn signal indicator bulb Removing Release catch 1 at...

Page 114: ...Removing Release headlight range control motor At right headlight by turning clockwise at left headlight by turning anti clockwise arrow By tilting control motor push ball end of positioning stem out...

Page 115: ...et for headlight housing Notes Broken off headlight fasteners can be replaced by installing repair set thus avoiding replacement of entire headlight Different repair sets are available for left and ri...

Page 116: ...adlights as of Model Year 2001 2 1 Servicing headlights as of Model Year 2001 Attention Disconnect battery earth strap before working on electrical system On vehicles fitted with telematics system act...

Page 117: ...document Copyright by AUDI AG 2 2 Exploded view of halogen headlight 1 Headlight housing 2 Speed nut 3 6 Nm 4 Left right headlight range control motor V48 V49 Removing and installing Page 124 Note If...

Page 118: ...ion in this document Copyright by AUDI AG 6 Side light bulb 12 V 5 W Bulb replacement Page 121 7 Bulb holder For side light bulb 8 Housing cover With seal 9 Main beam bulb H7 12 V 55 W Bulb replacemen...

Page 119: ...spect to the correctness of information in this document Copyright by AUDI AG 2 3 Exploded view of gas discharge headlight 1 Gas discharge lamp starter unit N195 Removing and installing Page 124 2 Bra...

Page 120: ...ument Copyright by AUDI AG 7 Left right headlight range control motor V48 V49 Removing and installing Page 124 Note If measures are taken which could affect headlight setting headlights are to be re a...

Page 121: ...s of information in this document Copyright by AUDI AG 11 Bulb holder For side light bulb 12 Housing cover With seal 13 Main beam bulb H7 12 V 55 W Bulb replacement Page 122 14 Bulb holder For turn si...

Page 122: ...liability with respect to the correctness of information in this document Copyright by AUDI AG 2 4 Removing and installing headlights Removing Left headlight If fitted remove front left cover arrows...

Page 123: ...ng TORX socket wrench through recess arrow 3 and screw out retaining bolt at bottom of headlight housing Note If necessary apply small quantity of body sealant to bolt to affix it to TORX wrench Vehic...

Page 124: ...g headlight Engage lug 1 of headlight in guide 2 in centre area Align headlight with body contours gap widths and secure Tighten bolts arrows 1 3 Install front bumper cover General Body Repairs Exteri...

Page 125: ...djusting screws 1 and 2 the same number of turns For lateral adjustment only turn adjusting screw 1 2 6 Adjusting headlights gas discharge headlights Special tools and workshop equipment required VAS...

Page 126: ...function 04 Basic setting Display on VAS 5051 1 Enter display group Use keypad 2 to enter 001 for Display group number 001 and confirm by touching Q key Display on VAS 5051 1 Basic setting 2 Display g...

Page 127: ...ew 2 Height adjustment screw To adjust height give adjusting screws 1 and 2 the same number of turns For lateral adjustment only turn adjusting screw 1 Display on VAS 5051 Touch s key to switch to dis...

Page 128: ...range control motor may be difficult to reach It may therefore also be necessary to remove battery Page 114 2 8 Replacing dipped beam bulb halogen headlight Preparation for bulb replacement Page 120 R...

Page 129: ...ch connector and close housing cover 2 10 Replacing side light bulb halogen headlight Preparation for bulb replacement Page 120 Removing Detach cover from headlight housing Pull holder arrow out of ho...

Page 130: ...housing Installing Install in reverse order paying attention to the following Notes Heed installation position Lug at top of bulb holder must engage in recess of bulb Retaining ring can only be fitte...

Page 131: ...connector and close housing cover 2 13 Replacing side light bulb gas discharge headlight Preparation for bulb replacement Page 120 Removing Detach cover from headlight housing Pull holder arrow out of...

Page 132: ...ling headlight range control motor Preparation for motor removal Page 120 Removing Release headlight range control motor At right headlight by turning anti clockwise at left headlight by turning clock...

Page 133: ...rning clockwise arrow By tilting control motor push ball end of positioning stem out of socket Detach cover from headlight housing Unplug connector 1 at gas discharge lamp by turning anti clockwise ar...

Page 134: ...lable for left and right headlight Parts List Sequence of operations Remove headlight with broken fastener Page 114 Remove remnants of broken off fastener at location marked with arrow Position fasten...

Page 135: ...n vehicles fitted with telematics system activate telematics control unit service mode before disconnecting battery Radio Telephone Navigation Repair Group 91 Heed if necessary obtain code for vehicle...

Page 136: ...o touch glass bulb with bare hands Secure bulb with spring clip Re attach connector and close housing cover Adjust fog light Page 97 3 4 Adjusting fog lights halogen headlights Specifications for fog...

Page 137: ...housing to bumper 5 3 6 Replacing fog light bulbs gas discharge headlights Removing Remove fog light Page 127 Release cover 1 by turning anti clockwise arrow and detach cover Unplug connector 2 Diseng...

Page 138: ...ng screw arrow to set height No provision is made for lateral adjustment 4 Servicing fog lights vehicles as of Model Year 2001 4 1 Servicing fog lights vehicles as of Model Year 2001 Attention Disconn...

Page 139: ...tion in this document Copyright by AUDI AG Note Action to be taken after re connecting power supply Page 7 4 2 Removing and installing fog lights Removing Audi A3 Release fasteners 1 4 with screwdrive...

Page 140: ...e out headlamp insert Unplug connector Installing Install in reverse order paying attention to the following Engage fog light on inside at bumper Adjust fog light Page 133 Tightening torque Component...

Page 141: ...Insert new bulb in housing taking care not to touch glass bulb with bare hands Heed bulb installation position Secure bulb with spring clip Re attach connector and close housing cover Adjust fog light...

Page 142: ...ctivate telematics control unit service mode before disconnecting battery Radio Telephone Navigation Repair Group 91 Heed if necessary obtain code for vehicles with encoded radio radio navigation syst...

Page 143: ...connect battery earth strap before working on electrical system On vehicles fitted with telematics system activate telematics control unit service mode before disconnecting battery Radio Telephone Nav...

Page 144: ...7 Rear fog light bulb 12 V 21 W 8 Turn signal indicator bulb 12 V 21 W As of Model Year 2001 Orange glass bulb 6 3 Removing and installing rear light Removing Open appropriate luggage compartment sto...

Page 145: ...tment Screw bulbs out of holders Installing Install in reverse order 7 Servicing high level brake light 7 1 Servicing high level brake light Attention Disconnect battery earth strap before working on...

Page 146: ...Unplug connector 6 Release fasteners and detach lens 3 with outer glass from bulb holder 2 Pull brake light bulbs 5 12 V 2 3 W out of bulb holder 1 Expanding rivet Installing Install in reverse order...

Page 147: ...nd installing number plate light Removing Note Fig only shows right number plate light Screw out bolts arrows in handle cover strip Prise bulb carrier out of handle cover strip Unplug connector Press...

Page 148: ...be taken after re connecting power supply Page 7 9 2 Safety precautions when working on airbag General Body Repairs Interior Repair Group 69 Airbag Safety Regulations Safety precautions when working...

Page 149: ...d lower steering column trim sections Vehicles without ESP Unplug connector 1 Use adhesive tape to secure coil connector with slip ring in installation position Release fasteners arrows and detach coi...

Page 150: ...umn switch Attention Coil connector with slip ring must not be turned out of centre position secure in installation position using adhesive tape Slacken off bolt arrow of clamp until steering column s...

Page 151: ...ng driver s storage compartment Storage compartments covers and trim panels Removing driver s storage com partment Install steering wheel and airbag unit General Body Repairs Interior Repair Group 69...

Page 152: ...t wipe 8 Terminal 53a Note Pin assignment for intermittent wiper control E38 Page 144 Terminal assignment for on board computer B vehicles up to 07 97 1 On board computer switch rocker to right 2 On b...

Page 153: ...nment for cruise control system C 2 Engine control unit 3 Engine control unit 4 Engine control unit 5 Engine control unit 6 Terminal 15 7 Engine control unit Terminal assignment for turn signal indica...

Page 154: ...il for immobilizer is attached to lock cylinder and cannot be replaced separately Lock cylinder must be replaced if reader coil is defective When replacing lock cylinders heed reader coil specificatio...

Page 155: ...ithout ignition key Insert steel wire or pin approx 1 5 mm in hole 1 as far as it will go at the same time pulling lock cylinder 2 with reader coil out of steering lock housing 3 Note If lock cylinder...

Page 156: ...nplug connector 1 at ignition starter switch Remove locking compound from both bolts arrows Slacken off bolts arrows slightly and pull ignition starter switch out of steering lock housing 2 Installing...

Page 157: ...arking aid 11 1 Servicing parking aid Attention Disconnect battery earth strap before working on electrical system On vehicles fitted with telematics system activate telematics control unit service mo...

Page 158: ...l unit J446 At rear right of luggage compartment beneath side trim Removing and installing Page 150 2 Rear parking aid warning buzzer H15 At rear left of luggage compartment beneath side trim Removing...

Page 159: ...lts 3 Detach holder 4 with parking aid control unit 2 Unscrew nuts 1 and detach parking aid control unit from holder Installing Install in reverse order Tightening torques Component Nm Control unit to...

Page 160: ...arking aid sender Fitting location In bumper on back Removing Unplug connector 1 at sender Press both retainer tabs aside arrows and press out sender inwards Note Second mechanic may be required to pr...

Page 161: ...Note Action to be taken after re connecting power supply Page 7 Attention High voltage On vehicles with gas discharge headlights always disconnect battery earth strap before working on gas dis charge...

Page 162: ...g Running Gear Front wheel Drive and Four wheel Drive Repair Group 42 4 Headlight range control unit J431 Fitting location on 3 door model In wheel housing on left beneath side trim at rear Removing a...

Page 163: ...General Body Repairs Interior Repair Group 70 Unplug connector Screw out bolts 1 and detach headlight range control unit 2 3 Speed nut Installing Install in reverse order Tightening torque Component N...

Page 164: ...13 1 Servicing ultrasonic interior monitor Attention Disconnect battery earth strap before working on electrical system On vehicles fitted with telematics system activate telematics control unit serv...

Page 165: ...m Trim Removing and installing B pillar trim Unplug connector Unscrew ultrasonic sensor 1 from B pillar trim arrows Installing Install in reverse order 13 3 Removing and installing interior monitor co...

Page 166: ...th 7 Left ultrasonic sensor analog signal 8 Left ultrasonic sensor 40 kHz pulse 9 Deactivation switch 10 Left M27 and right M28 door warning lamp output 11 Earth terminal 31 12 Warning lamp interior m...

Page 167: ...vigation Repair Group 91 Heed if necessary obtain code for vehicles with encoded radio radio navigation system RNS Disconnect battery earth strap with ignition switched off Note Action to be taken aft...

Page 168: ...talling switches in centre console as of Model Year 2001 Removing Remove radio monitor navigation system Radio Telephone Navigation Repair Group 91 Unclip trim for switch module arrows Detach trim for...

Page 169: ...dy Repairs Interior Repair Group 68 Use flat screwdriver to carefully prise seat heating switch out of mount arrow Unplug connector Installing Install in reverse order paying attention to the followin...

Page 170: ...itioner On vehicles with air conditioner front seat heating switches are integrated into operating and display unit E87 Remove air conditioner operating element Air Conditioner Repair Group 87 Use sma...

Page 171: ...sing arrow 3 Unplug connector Installing Install in reverse order paying attention to the following Press switch into switch housing until catch engages 1 7 Removing and installing adjuster for manual...

Page 172: ...ial tools and workshop equipment required Hook for front end 3370 Removing Open glove box Use special tool 3370 to pull off right dash panel end trim arrow Squeeze both release tabs together arrows 1...

Page 173: ...tch Pull function selection switch out of storage compartment Slide back foam sheath and unplug connectors Installing Install in reverse order 1 10 Removing and installing mirror adjustment switch 3 d...

Page 174: ...out bolt arrow Release top part of recessed handle moulding 1 and detach Unplug connectors Use small screwdriver to carefully release fasteners arrows at retaining frame 1 Pull mirror adjustment swit...

Page 175: ...oor model Removing Remove front door trim General Body Repairs Interior Repair Group 70 Use small screwdriver to carefully release fasteners arrows Press window lifter switch downwards out of door tri...

Page 176: ...s A Pull window lifter switch 1 downwards out of mount 2 Installing Install in reverse order paying attention to the following Press window lifter switch into switch mount until fasteners engage 1 14...

Page 177: ...ow lifter switch into switch mount until fasteners engage 1 15 Removing and installing rear door window lifter switch Removing Screw out bolt arrow Release top part of recessed handle moulding 1 and d...

Page 178: ...t of interior light reading light Installing Install in reverse order paying attention to the following Plug in connector Tightening torque Component Nm Sun roof switch to interior light reading light...

Page 179: ...d press central locking switch 1 out of driver s door trim Installing Install in reverse order 1 19 Removing and installing button for interior monitor Removing Remove B pillar trim on driver s side G...

Page 180: ...ed separately in the event of a fault Replacing tailgate boot lid lock General Body Repairs Exterior Repair Group 55 2 Servicing immobilizer 2 1 Servicing immobilizer Attention Disconnect battery eart...

Page 181: ...set with 2 piece sticker Note Stickers on key tag of new lock set provide identification of mechanical lock Detach right sticker 2 with bar code from key ring of new lock set and dispose of it Pull le...

Page 182: ...r coil wire at connector between ignition starter switch and dash panel insert Start engine Engine must not run and warning lamp must flash Start immobilizer self diagnosis and interrogate fault memor...

Page 183: ...p lens at interior light reading light arrows Screw out bolts 1 and 2 Release retainer tabs arrows and take interior light reading light out of roof opening Unplug connector Installing Install in reve...

Page 184: ...g light arrows Take bulb 2 12 V 10 W for interior light out of clamp type holder Twist bulb 1 or 3 12 V 5 W for reading light out of holder Installing Install in reverse order paying attention to the...

Page 185: ...h respect to the correctness of information in this document Copyright by AUDI AG Removing Unclip lens at interior light arrows Use special tool 3370 to carefully pull off cover for reading light If f...

Page 186: ...arrows and take interior light reading light out of roof opening Unplug connectors Installing Install in reverse order paying attention to the following Engage interior light and tighten to 1 Nm Press...

Page 187: ...12 V 10 W out of clamp type holder Installing Install in reverse order paying attention to the following Press on lens for interior light until it engages 3 6 Replacing bulbs for front reading light a...

Page 188: ...r paying attention to the following Press on cover for reading light until it engages 3 7 Removing and installing rear interior light up to Model Year 1999 Special tools and workshop equipment require...

Page 189: ...g bulb for rear interior light up to Model Year 1999 Removing Remove rear interior light Page 180 Take bulb 2 12 V 10 W arrow for interior light out of clamp type holder Installing Install in reverse...

Page 190: ...l in reverse order paying attention to the following Insert interior light reading light in roof opening and engage 3 10 Replacing bulb for rear interior light reading light as of Model Year 2000 Remo...

Page 191: ...he following Plug in connector Insert luggage compartment light in opening and engage on opposite side 3 12 Removing and installing glove box light Notes Bulb replacement involves removing glove box l...

Page 192: ...lb for make up mirror light 12 V 5 W Removing Use flat screwdriver to carefully prise out make up mirror light at recess arrow Unplug connector If fitted pull off cover over bulb arrow Take bulb out o...

Page 193: ...Insert door safety light entry light in opening and engage on opposite side 4 Servicing lock cylinder heater 4 1 Servicing lock cylinder heater Attention Disconnect battery earth strap before working...

Page 194: ...alling Install in reverse order 5 Servicing horns 5 1 Servicing horns Attention Disconnect battery earth strap before working on electrical system On vehicles fitted with telematics system activate te...

Page 195: ...ing Install in reverse order 6 Servicing connection socket for towing hitch 6 1 Servicing connection socket for towing hitch Attention Disconnect battery earth strap before working on electrical syste...

Page 196: ...ontact switch F216 and press connector 1 out of con nection socket Installing Install in reverse order 6 3 Terminal assignment at connection socket for towing hitch 1 Terminal BL left turn signal indi...

Page 197: ...ical system On vehicles fitted with telematics system activate telematics control unit service mode before disconnecting battery Radio Telephone Navigation Repair Group 91 Heed if necessary obtain cod...

Page 198: ...document Copyright by AUDI AG Unscrew nuts 1 5 Lay bare wires Detach fuse box for main fuse Note Precise assignment of fuse box can be seen from appropriate current flow diagram Current Flow Diagrams...

Page 199: ...ior Repair Group 68 Screw out bolts B of fuse box A Release clips C and detach fuse box from central tube for dash panel Disengage and lay bare wiring harness at dash panel central tube Cut open cable...

Page 200: ...central tube 3 1 4 Removing and installing central electrics and 13 position relay carrier Removing Remove driver s storage compartment General Body Repairs Interior Repair Group 68 Screw out bolts C...

Page 201: ...ms Electrical Fault finding and Fitting Locations binder Installing Install in reverse order Tightening torque Component Nm Central electrics and 13 position relay carrier to holder 2 1 5 Left connect...

Page 202: ...tion Right connector point arrow is located in right footwell beneath A pillar trim Remove A pillar trim General Body Repairs Interior Repair Group 70 1 Central locking brown 2 Electric window lifter...

Page 203: ...lectrical Fault finding and Fitting Locations binder 2 Wiring harness and connector repair 2 1 Wiring harness and connector repair Attention Disconnect battery earth strap before working on electrical...

Page 204: ...0 35 mm2 wire Notes The wiring harness repair set VAS 1978 contains three different repair wire cross sections 0 5 mm2 1 5 mm2 4 0 mm2 and the appropriate crimp connectors A 0 35 mm2 wire has to be re...

Page 205: ...ause of damage e g sharp body edges defective loads corrosion Wires forming part of airbag system and screened wires such as speed and knock sensor wires are never to be repaired Further information r...

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